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Yamaha GRIZZLY 700 2013, Owner'S Manual, Page: 14 / 174

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Yamaha GRIZZLY 700 2013 Owner'S Manual Download Page 14

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YAMAHA MOTOR CO., LTD.
2500 SHINGAI, IWATA, JAPAN

YFM700FWA
34.0 kW
294 kg

2013

2ES-F155A-00

37S-F816N-00

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0.5 kg

  (   1 lb )

YAMAHA MOTOR CO., LTD.
2500 SHINGAI, IWATA, JAPAN

YFM700FWAD
34.0 kW
294 kg

2013

2BG-F155A-00

YAMAHA

1HP-F811R-00

6  YFM700DE

6  YFM700PE/YFM700PHE/ 
    YFM700PSE/YFM700PLE

7

8

U2BG60E0.book  Page 3  Monday, May 20, 2013  3:04 PM

Summary of Contents for GRIZZLY 700 2013

Page 1: ...TAIRE MANUAL DEL PROPIETARIO 2BG 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 2013 05 0 3 1 CR E F S DIC183 Original instructions Notice originale Manual original ...

Page 3: ...ontains important safety information WARNING OWNER S MANUAL YFM700DE YFM700PE YFM700PHE YFM700PSE YFM700PLE This ATV should not be ridden by anyone under 16 years of age 2BG F8199 60 E0 U2BG60E0 book Page 1 Monday May 20 2013 3 04 PM ...

Page 4: ... Rijk The Netherlands Signature Akihiro Tsuzuki 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 EEC the following standards and or technical specifications were consulted Title and or number and date of issue of s...

Page 5: ...ds Signature Akihiro Tsuzuki 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 EEC the following standards and or technical specifications were consulted Title and or number and date of issue of standards and or spe...

Page 6: ...sic 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 ...

Page 7: ...e 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 inf...

Page 8: ... Please check your local riding laws and regulations before operating this ATV EBU17410 YFM700DE YFM700PE YFM700PHE YFM700PSE YFM700PLE OWNER S MANUAL 2013 by Yamaha Motor Co Ltd 1st edition May 2013 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 U2BG60E0 book Page 1 Monday May 20 2013 3 04 PM ...

Page 9: ...ke 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 fastener...

Page 10: ...moving the radiator grills 8 19 Checking the spark plug 8 20 Engine oil and oil filter cartridge 8 22 Final gear oil 8 26 Differential gear oil 8 29 Coolant 8 31 Cleaning the air filter element 8 39 Cleaning the spark arrester 8 42 V belt case drain plug 8 44 Adjusting the throttle lever free play 8 44 Valve clearance 8 45 Adjusting the drive select lever safety system cable 8 45 Brakes 8 45 Check...

Page 11: ...se 8 59 Replacing a headlight bulb 8 61 Adjusting a headlight beam 8 62 Replacing the tail brake light bulb 8 63 Removing a wheel 8 64 Installing a wheel 8 64 Troubleshooting 8 65 Troubleshooting charts 8 66 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 U2BG60E0 book Page 3 Monday May 20 2013 3 04 PM ...

Page 12: ...ls on 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 5 6 7 9 8 10 11 U2BG60E0 book Page 1 Monday May 20 2013 3 04 PM ...

Page 13: ... 15 kgf 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 1 2 3 4 5 U2BG60E0 book Page 2 Monday May 20 2013 3 04 PM ...

Page 14: ... kW 294 kg 2013 2ES F155A 00 37S F816N 00 0 5 kg 1 lb YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWAD 34 0 kW 294 kg 2013 2BG F155A 00 YAMAHA 1HP F811R 00 6 YFM700DE 6 YFM700PE YFM700PHE YFM700PSE YFM700PLE 7 8 U2BG60E0 book Page 3 Monday May 20 2013 3 04 PM ...

Page 15: ...1 4 1 37S F816S 00 1P0 F816R 00 YAMAHA 9 10 11 U2BG60E0 book Page 4 Monday May 20 2013 3 04 PM ...

Page 16: ...e from 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 this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER use on paved roads NEVER carry passengers NEVER use with drugs or alcohol NEVER store fuel or flammabl...

Page 17: ... loss 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 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 and all other load re...

Page 18: ...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 U2BG60E0 book Page 7 Monday May 20 2013 3 04 PM ...

Page 19: ...1 8 1 For Oceania 1 2 3 4 5 6 8 7 9 U2BG60E0 book Page 8 Monday May 20 2013 3 04 PM ...

Page 20: ...30 YAMAHA 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 SEVERE INJURY or DEATH 1 2 3 4 U2BG60E0 book Page 9 Monday May 20 2013 3 04 PM ...

Page 21: ...top Avoid 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 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 NEVER operate this A...

Page 22: ...truction 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 OWN...

Page 23: ... 16 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 child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV This vehicle is intended for off road use only Do not operate on any paved surfaces such as sidew...

Page 24: ...ssive 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 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 sudde...

Page 25: ...ing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type ...

Page 26: ... and 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 happened In the event of a breakdown 1 If your vehicle will not restart or is not in safe operating condition turn off the main switch and engine stop switch If the breakdown oc curs at twilight or nig...

Page 27: ...and 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 when mounting accessories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground...

Page 28: ...so 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 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 ru...

Page 29: ... 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 U2BG60E0 book Page 1 Monday May 20 2013 3 04 PM ...

Page 30: ...r 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 U2BG60E0 book Page 2 Monday May 20 2013 3 04 PM ...

Page 31: ...re 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 U2BG60E0 book Page 1 Monday May 20 2013 3 04 PM ...

Page 32: ...ght 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 7 On ...

Page 33: ... 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 page 4 7 ...

Page 34: ...ear 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 synchronizin...

Page 35: ...RIP 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 ...

Page 36: ...SELECT 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 37: ...play 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 thi...

Page 38: ...he point that the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 55 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 differe...

Page 39: ...p 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 ...

Page 40: ...he ATV handles differently in four wheel drive than in differential gear lock in some circum stances Changing from four wheel drive to dif ferential gear lock or vice versa while moving may cause the ATV to handle differently unex pectedly This could distract the operator and increase the risk of losing control and causing an accident WARNING EWB00140 Always ride at a slow speed when the ATV is in...

Page 41: ...upplied 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 s...

Page 42: ...sh 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 lock to engage or disen gage 1 Differential gear lock lever 2 On Command ...

Page 43: ... the 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...

Page 44: ... operation You could lose control resulting in an accident EWB00241 3 Tighten the locknut EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull the brake lever toward the handlebar grip EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handleba...

Page 45: ...perating the drive select lever and driving in reverse section on page 6 2 for the drive select lever operation EBU27350 Fuel tank cap To remove the fuel tank cap Open the fuel tank cap cover and then remove the fuel tank cap by turning it counterclockwise 1 Brake pedal 1 Rear brake lever 1 Drive select lever U2BG60E0 book Page 15 Monday May 20 2013 3 04 PM ...

Page 46: ...g 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 47: ...r 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 1 M...

Page 48: ...ce 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 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 P...

Page 49: ...ront 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 U2BG60E0 book Page 19 Mo...

Page 50: ... 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 compartmen...

Page 51: ... 485 lb for the ATV EBU19146 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 52: ...g preload and thereby soften the suspension Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 U2BG60E0 book Page 22 Monday May 20 2013 3...

Page 53: ...ory off 3 Start the engine See page 6 1 4 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 5 Turn the accessory on 6 When the auxiliary DC jack is not being used cover it with the cap NOTICE ECB00120 Do not use accessories requiring more than the above maximum capacity This may overload the circuit and cause the fuse to blow 1 Auxiliary DC jack cap 1 Auxiliary...

Page 54: ...he 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 U2BG60E0 book Page 24 Monday May 20 2013 3 04 PM ...

Page 55: ...y a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 16 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 22 Final gear oil Check ATV for ...

Page 56: ...Throttle 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 44 Control cables Make sure that operation is smooth Lubricate if necessary 8 52 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Brake...

Page 57: ...ssary See page 8 31 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 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 adjus...

Page 58: ... 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 O...

Page 59: ...en the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended tire pressure Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum tire pressure Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi 1 Low pressure tire gauge U2BG60E0 book Pag...

Page 60: ...n approved for this model by Yamaha Motor Manufacturing Corporation of America 1 Tire wear limit Front Manufacturer model YFM700DE MAXXIS MU19A YFM700PE CHENG SHIN C828 AUS NZL YFM700PE MAXXIS MU19A EUR FRA GBR YFM700PHE MAXXIS MU19A YFM700PLE CHENG SHIN C828 AUS NZL YFM700PLE MAXXIS MU19A EUR FRA GBR YFM700PSE CHENG SHIN C828 AUS NZL YFM700PSE MAXXIS MU19A EUR FRA GBR Size AT25 x 8 12 Type Tubele...

Page 61: ...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 Manufacturer model YFM700DE MAXXIS MU20A YFM700PE CHENG SHIN C828 AUS NZL YFM700PE MAXXIS MU20A EUR FRA GBR YFM700PHE MAXXIS MU20A YFM700PLE CHENG SHIN C828 AUS NZL YFM700PLE MAXXIS MU20A EUR FRA GBR YFM700PSE CHENG SHIN C828 AUS ...

Page 62: ...oolant 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 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 l...

Page 63: ...d 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 64: ... people or ob stacles behind you When it is safe to proceed go slowly 1 Bring the ATV to a complete stop 2 Apply the brake pedal The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal 3 Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide 1 Drive select lever 2 L Low range 3 H Hig...

Page 65: ...iven in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various...

Page 66: ...e engine and shift the drive select lever into the park position EBU29900 Parking on a slope WARNING EWB00860 Avoid parking on hills or other inclines Park ing on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident If you must park on an incline place the ATV transversely across the incline stop the engine shift the drive select lever to the park...

Page 67: ...d aftermarket products similar in design and quality to genuine Yamaha Accesso ries recognize that some aftermarket accessories or modifications are not suitable because of poten tial safety hazards to you or others Installing after market products or having other modifications performed to your ATV that change any of the ve hicle s design or operation characteristics can put you and others at gre...

Page 68: ... trailer can change the stability and han dling of an ATV You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable Do not exceed the maximum tongue weight You can measure tongue weight with a bath room scale Put the tongue of the loaded trailer on the scale with the ...

Page 69: ...shifting 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 heavi...

Page 70: ...7 1 7 EBU21141 RIDING YOUR ATV U2BG60E0 book Page 1 Monday May 20 2013 3 04 PM ...

Page 71: ...ual 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 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 72: ...1390 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 WA...

Page 73: ...NG Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating w...

Page 74: ...each time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual WARNING Failure to inspect the ATV before operating it and to maintain it prop erly increases the possibility of an accident or equipment damage EWB01431 Speed limiter For ...

Page 75: ...centered 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 t...

Page 76: ...all off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident EWB01471 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 220 0 kg 485 ...

Page 77: ... 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 78: ...rfaces 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 U2BG60E0 bo...

Page 79: ...ich 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 ...

Page 80: ...ion 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 U2BG60E0 book Page 11 M...

Page 81: ... 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 ...

Page 82: ...of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside whil...

Page 83: ... 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 ...

Page 84: ... 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 85: ... 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 86: ...ither the front or rear brake be cause the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01632 ...

Page 87: ...It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel C...

Page 88: ...r 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 drai...

Page 89: ...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 U2BG60E0 book Page 20 Monday May 20 2013 3 04 PM ...

Page 90: ...o 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 91: ...f time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are re duced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each sectio...

Page 92: ...eed 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 93: ...urn 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 6 for more information about carbon monoxide WARNING EWB02690 ...

Page 94: ...al 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 pressu...

Page 95: ... 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 necessar...

Page 96: ... reed valve and hose for damage Replace any damaged parts if necessary 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 U2BG60E0 book Page 4 Monday May 20 2013 3 04 PM ...

Page 97: ...with 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 o...

Page 98: ...e 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 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened NO ITEM CHECK OR...

Page 99: ...d 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 20 Differential gear oil Change Check ATV for oil leakage and correct if neces sary NO ITEM CHECK OR M...

Page 100: ...place 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 er comes first month 1 3 6 6 12 km mi 32...

Page 101: ...at 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 U2BG60E0 book Page 9 Monday May 20 2013 3 04 PM ...

Page 102: ... jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU27387 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 U2BG60E0 book Page 10 Monday May 20 2013 3 04 PM ...

Page 103: ...l 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 U2BG60E0 book Page 11 Monday May 20 2013 3 04 PM ...

Page 104: ...nel upward to remove it To install the panel 1 Place the panel in the original position and then install the quick fasteners 1 Front carrier 2 Carrier bolt upper 1 Carrier bolt lower 1 Panel B 2 Quick fastener U2BG60E0 book Page 12 Monday May 20 2013 3 04 PM ...

Page 105: ...er screws and then pull the panel upward to remove it To install the panel 1 Place the panel in the original position and then install the quick fastener screws Tightening torques Carrier bolt upper 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt lower 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 fastener screw U2BG60E0 book Page 13 Monday May 20 2013...

Page 106: ...els 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 1 Panel D 2 Quick fastener screw 1 Bolt U2BG60E0 book Page 14 Monday May 20 2013 3 04 PM ...

Page 107: ...l a panel 1 Place the panel in the original position and then install the bolt and quick fastener screw 2 Install panels A and C 1 Panel E 2 Quick fastener screw 1 Bolt U2BG60E0 book Page 15 Monday May 20 2013 3 04 PM ...

Page 108: ...Pull the panel downward while pushing the projection To install a panel 1 Place the panel in the original position 1 Panel F 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection 1 Panel G 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection U2BG60E0 book Page 16 Monday May 20 2013 3 04 PM ...

Page 109: ...l H To remove the panel 1 Remove the seat See page 4 18 2 Remove the 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 U2BG60E0 book Page 17 Monday May 20 2013 3 04 PM ...

Page 110: ... on the areas shown To install the panel 1 Place the panel in the original position and then install the quick fasteners 1 Rear carrier 2 Carrier bolt upper 1 Carrier bolt lower 1 Panel H 2 Quick fastener 2 1 U2BG60E0 book Page 18 Monday May 20 2013 3 04 PM ...

Page 111: ...Remove the quick fastener pull the radiator grill outward at the top and then pull it upward To install a radiator grill Place the radiator grill in its original position and then install the quick fastener Tightening torques Carrier bolt upper 60 Nm 6 0 m kgf 43 ft lbf Carrier bolt lower 60 Nm 6 0 m kgf 43 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Radiator grill 2 Quick fa...

Page 112: ...ddition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden nor...

Page 113: ...necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification To install the spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK CPR7EA 9 1 S...

Page 114: ...e 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 level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least 10 minutes until the oil settles for an accurate reading 3 Remove the acce...

Page 115: ... the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level NOTICE Be sure the engine oil is at the correct level otherwise engine damage may result ECB00851 7 Insert the dipstick completely into the oil filler hole 8 Install the access cover by turning it clock wise 1 Engine oil dipstick 1 Maximum level mark 2 Minimum level mark U2BG60E0 book Page 23 Monda...

Page 116: ...ain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 5 9 if the oil filter cartridge is not being replaced 5 Remove panel F See page 8 10 6 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer 7 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge 1 Engine oil drain bolt 2 Gasket 1 2...

Page 117: ...d torque with a torque wrench 9 Install panel F 10 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the speci fied torque 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf U2BG60E0 book Page 25 Monday May 20 2013 3 04 PM ...

Page 118: ...for oil leakage If oil is leaking immediately turn the engine off and check for the cause 13 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 14 Install the access cover by turning it clock wise EBU27306 Final gear oil The final gear case must be checked for oil leak age before each ride If any leakage is found have a Yamaha dealer check and re...

Page 119: ...e to raise it to the correct level 4 Check the gaskets for damage and replace them if necessary 5 Install the oil level check bolt the oil filler bolt and their gasket and then tighten the bolts to the specified torques 1 Final gear oil 2 Gasket 3 Final gear oil level check bolt 4 Correct oil level 1 2 4 3 1 Final gear oil filler bolt 2 Gasket Tightening torques Final gear oil level check bolt 10 ...

Page 120: ...rain bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended final gear oil to the brim of the check hole as shown NOTICE Be sure no foreign material enters the final gear case ECB00421 1 Final gear oil drain bolt 2 Gasket 1 2 Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil 2 Gasket 3 Final gear oil level check ...

Page 121: ...s at the in tervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface 2 Remove the differential gear oil filler bolt and its gasket and then check the oil level in the differential gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil...

Page 122: ... the oil from the differential gear case 4 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended differential gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material en ters the differential gear case ECB00411 Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Differential g...

Page 123: ...periodic maintenance and lubrication chart EBU27126 To check the coolant level 1 Place the ATV on a level surface TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser voir TIP The coolant should be between the minimum and maximum level marks 1 Differential gear oil filler bolt 2 Gasket 3 Differential ...

Page 124: ...e engine If water has been used instead of coolant re place it with coolant as soon as possible otherwise the cooling system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze con tent of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECB01011 1 Maximum level mark 2 Minimum l...

Page 125: ...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 removing the bolts and nuts 4 Place a container under the engine and then remove the coolant drain bolt and its gasket Use a trough or a similar object as sho...

Page 126: ... Remove the coolant reservoir cap 8 Disconnect the coolant reservoir hose on the coolant reservoir side and then drain the cool ant from the coolant reservoir 1 Coolant drain bolt 2 Gasket 1 Trough 1 2 1 1 Radiator cap U2BG60E0 book Page 34 Monday May 20 2013 3 04 PM ...

Page 127: ...le soft water may be used for refilling Do not use hard water or salt water since they are harmful to the engine ECB00991 14 Loosen the water pump air bleed bolt without removing it to allow all of the air to escape from the air bleed bolt hole 1 Coolant reservoir hose Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Antifreeze water mixture ratio 1 1 Recommended antifreeze High qua...

Page 128: ...e clamp screw and then remove the V belt cooling duct 18 Loosen the cylinder head air bleed bolt with out removing it to allow all of the air to escape from the air bleed bolt hole 1 Water pump air bleed bolt Tightening torque Water pump air bleed bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 1 V belt cooling duct 2 Clamp screw U2BG60E0 book Page 36 Monday May 20 2013 3 04 PM ...

Page 129: ... cooled add sufficient coolant until it reaches the top of the radiator and then install the ra diator cap 24 Start the engine and then 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 installing the bolts and nuts and then tighten them to the specified...

Page 130: ...nels 1 Footboard nut 2 Footboard bolt A 3 Footboard bolt B 3 1 2 1 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 Footboard bolt B 7 Nm 0 7 m kgf 5 1 ft lbf 4 1 2 3 U2BG60E0 book Page 38 Monday May 20 2013 3 04 PM ...

Page 131: ...usty 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 ...

Page 132: ...move the sponge material and the air filter 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 U2BG60E0 book Page 40 Monday May 20 2013 3 04 PM ...

Page 133: ... 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 wit...

Page 134: ...heck the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the throttle body and the rubber joint mani fold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air en tering the engine EBU28903 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remo...

Page 135: ...de of the tailpipe housing 4 Check the gasket for damage and replace it if necessary 5 Make sure the gasket is properly positioned then insert the tailpipe into the muffler and align the bolt holes 6 Install the bolts and tighten them to the speci fied torque 1 Tailpipe bolt 1 1 1 Gasket 2 Spark arrester 3 Tailpipe Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf 3 2 1 U2BG60E0 book Page...

Page 136: ...the case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the water may affect other engine parts EBU29702 Adjusting the throttle lever free play The throttle lever free play should be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The throttle lever free play should measure 3 0 5 ...

Page 137: ... 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 stretch es with use which can result in improper function Therefore the safety system cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EBU29601 ...

Page 138: ... 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 brak...

Page 139: ...brake 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 perfor mance Clean the filler cap before removing Use only DOT 4 brake fluid from a sealed contain er 1 Minimum level mark 2WD 4WD 1 1 Minimum level mark Specified brake fluid DOT 4 U2BG60E0 book Pag...

Page 140: ...pads for wear 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 EBU24292 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrication chart In addition have the oil seals of the master cylinders and calipers as well as the brake hose...

Page 141: ...ays perform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting the brake pedal free play check the rear brake pads for wear The brake pedal free play should measure 1 0 6 0 mm 0 04 0 24 in as shown If the free play is in correct adjust it as follows 1 No brake lever free play 1 No brake lever free play U2BG60E0 book Page 49 Monday May 20 2013 3 04...

Page 142: ...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 U2BG60E0 book Page 50 Monday May 20 2013 3 04 PM ...

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 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 U2BG60E0 book Page 51 Monday ...

Page 144: ... 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 front and rear brake lev...

Page 145: ...edal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel G See page 8 10 Recommended lubricant Lithium soap based grease U2BG60E0 book Page 53 Monday May 20 2013 3 04 PM ...

Page 146: ... 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 gre...

Page 147: ...anger 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 148: ...ttery 1 Remove panel A See page 8 10 2 Remove the front carrier by removing the bolts 1 Carrier bolt under the fenders 1 Front carrier 2 Carrier bolt upper 1 Carrier bolt lower U2BG60E0 book Page 56 Monday May 20 2013 3 04 PM ...

Page 149: ...with optional electri cal accessories NOTICE ECB00931 To charge a VRLA Valve Regulated Lead Acid battery a special constant voltage battery charger is required Using a conventional bat tery charger will 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 fo...

Page 150: ...must be connected before the negative lead ECB01110 3 Install the battery holding plate by installing the nuts 4 Install the front carrier by installing the bolts and tightening them to the specified torques 5 Install the panel 1 Positive battery lead red 2 Negative battery lead black 1 2 Tightening torques Carrier bolt upper 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt lower 34 Nm 3 4 m kgf 25 ft lbf C...

Page 151: ...t as follows 1 Turn the key to off and turn off all elec trical circuits 1 Fuse box 2 Main fuse 3 EPS fuse for EPS model 4 Fuel injection system spare fuse 5 Fuel injection system fuse 1 Auxiliary DC jack fuse 2 Four wheel drive motor fuse 3 Ignition fuse 4 Radiator fan fuse 5 Signaling system fuse 6 Headlight fuse 7 Spare fuse U2BG60E0 book Page 59 Monday May 20 2013 3 04 PM ...

Page 152: ...ubstitute object can cause damage to the electrical system which could lead to a fire EWB02172 3 Turn the key to on and turn on the elec trical circuits to check if the devices operate 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...

Page 153: ...ht bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the headlight bulb cover 3 Disconnect the headlight coupler 1 Cover at the rear of the headlight 1 Headlight bulb cover 1 Headlight coupler U2BG60E0 book Page 61 Monday May 20 2013 3 04 PM ...

Page 154: ...and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner ECB00651 6 Connect the headlight coupler 7 Install the headlight bulb cover NOTICE Make sure the headlight bulb cover is se curely fitted and seated properly ECB01080 8 Install the cover at the rear of the headlight 9 Adjust the headlight beam if necessary EBU25551 Adjusting a headlight beam NOTICE ECB00690 It i...

Page 155: ...f 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 counter clockwise 3 Remove the burnt out bulb by pushing it in and turning it counterclockwise 1 Headlight beam adjusting screw 1 Tail brake light bulb holder 1 Tail brake light bulb U2BG60E0 book Page 63 Monday May 20 2013 3 04 ...

Page 156: ...levate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU25701 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side to wards th...

Page 157: ... 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 explode causing ...

Page 158: ...ve 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 compression Dry Wet Operate the electric starter Have a Yamaha dealer check the ATV The engine does not start Check the ignition Operate the electric starter 2 Battery The engine turns over qu...

Page 159: ...r can be temporarily used instead provided that it is changed to the rec ommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If the engine overheats...

Page 160: ...ion 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 w...

Page 161: ... 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 162: ...e it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery see page 8 55 TIP Make any necessary repairs before storing the ATV U2BG60E0 book Page 3 Monday May 20 2013 3 04 PM ...

Page 163: ... seat EN1032 ISO5008 YFM700DE Will not exceed 0 5 m s YFM700PE Will not exceed 0 5 m s EUR FRA GBR YFM700PHE Will not exceed 0 5 m s YFM700PLE Will not exceed 0 5 m s EUR FRA GBR YFM700PSE Will not exceed 0 5 m s EUR FRA GBR Vibration on handlebar EN1032 ISO5008 YFM700DE Will not exceed 2 5 m s YFM700PE Will not exceed 2 5 m s EUR FRA GBR YFM700PHE Will not exceed 2 5 m s YFM700PLE Will not exceed...

Page 164: ...y 0 22 L 0 23 US qt 0 19 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 24 L 0 25 US qt 0 21 Imp qt Radiator capacity including all routes 1 99 L 2 10 US qt 1 75 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal F...

Page 165: ...A YFM700PE CHENG SHIN C828 AUS NZL YFM700PE MAXXIS MU19A EUR FRA GBR YFM700PHE MAXXIS MU19A YFM700PLE CHENG SHIN C828 AUS NZL YFM700PLE MAXXIS MU19A EUR FRA GBR YFM700PSE CHENG SHIN C828 AUS NZL YFM700PSE MAXXIS MU19A EUR FRA GBR Rear tire Type Tubeless Size AT25 x 10 12 Manufacturer model YFM700DE MAXXIS MU20A YFM700PE CHENG SHIN C828 AUS NZL YFM700PE MAXXIS MU20A EUR FRA GBR YFM700PHE MAXXIS MU2...

Page 166: ...d operation Specified brake fluid DOT 4 Rear brake Type Disc brake Operation Left hand and right foot operation Specified brake fluid DOT 4 Front suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 193 mm 7 6 in Rear suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 232 mm 9 1 in Electrical system Ignition syst...

Page 167: ...or light LED Low range indicator light LED Differential gear lock indicator light LED Fuses Main fuse 40 0 A Fuel injection system fuse 15 0 A EPS fuse YFM700PE 40 0 A YFM700PHE 40 0 A YFM700PLE 40 0 A YFM700PSE 40 0 A Headlight fuse 10 0 A Signaling system 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 EBU30401 For Europe ...

Page 168: ... other sources of noise etc i e the number of machines and other adjacent process es and the length of time for which an operator is exposed to the noise Also the permissible expo 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 U2BG60E0 book Page 6 Monday May 20 2013 3 04 PM ...

Page 169: ...DEL 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 label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Ya...

Page 170: ...11 2 11 1 Model label U2BG60E0 book Page 2 Monday May 20 2013 3 04 PM ...

Page 171: ...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 45 E Engine break in 6 4 Engine oil 5 3 Engine oil and oil filter cartridge 8 22 Engine stop switch 4 7 Engine trouble warning light 4 3 EPS warning light for EPS model 4 3 F Final gear oil 5 3 8 26 Four wheel drive differential gear lock indic...

Page 172: ...everse 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 54 Starting the engine 6 1 Start switch 4 8 Steering shaft lubricating 8 55 Storage 9 2 Storage compartments 4 18 T Tail brake light bul...

Page 173: ...U2BG60E0 book Page 3 Monday May 20 2013 3 04 PM ...

Page 174: ...N APPROVED 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 roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AN...

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