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Yamaha GRIZZLY 700 FI YFM7FGPW, Owner'S Manual

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Yamaha GRIZZLY 700 FI YFM7FGPW Owner'S Manual Download Page 86

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EBU21653

PERIODIC MAINTENANCE AND MINOR REPAIR

EBU21670

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

WARNING

EWB01840

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

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

EBU27110

Owner’s manual and tool kit 

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

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

3. Owner’s tool kit

U3B460E0.book  Page 1  Friday, May 12, 2006  2:51 PM

Summary of Contents for GRIZZLY 700 FI YFM7FGPW

Page 1: ...YFM7FGPW OWNER S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO 3B4 28199 60 ...

Page 2: ...PRINTED IN JAPAN 2006 05 1 4 1 CR E F S PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO YAMAHA MOTOR CO LTD ...

Page 3: ...OWNER S MANUAL YFM7FGPW 3B4 28199 60 E0 U3B460E0 book Page 1 Friday May 12 2006 2 51 PM ...

Page 4: ... number and date of issue of the other Directives of EEC If applicable 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 specifications 2500 Shingai Iwata Japan Place and date of issue Takaharu Ishima Name and j...

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

Page 6: ...o change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage to the ATV A NOTE provides key information to make procedures easier o...

Page 7: ...face paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM7FGPW OWNER S MANUAL 2006 by Yamaha Motor Co Ltd 1st edition April 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U3B460E0 book Page 1 Friday May 12 2006 2 51 PM...

Page 8: ...e lever 4 14 Drive select lever 4 15 Fuel tank cap 4 15 Fuel 4 16 Seat 4 17 Storage compartments 4 18 Front carrier 4 21 Rear carrier 4 21 Adjusting the front and rear shock absorber assemblies 4 21 Auxiliary DC jack 4 22 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Differential gear oil 5 3 Coolant 5 3 Front and rear brakes 5 4 Throttle lever 5 ...

Page 9: ...d installing panels 8 8 Checking the spark plug 8 20 Engine oil and oil filter cartridge 8 22 Final gear oil 8 26 Differential gear oil 8 28 Coolant 8 30 Cleaning the air filter element 8 36 Cleaning the spark arrester 8 40 V belt case drain plug 8 42 Adjusting the engine idling speed 8 42 Adjusting the throttle cable free play 8 43 Valve clearance 8 44 Adjusting the drive select lever safety syst...

Page 10: ...ckle pivots 8 54 Lubricating the knuckle shafts 8 54 Lubricating the steering shaft 8 54 Battery 8 55 Replacing a fuse 8 56 Replacing a headlight bulb 8 58 Adjusting a headlight beam 8 61 Replacing the tail brake light bulb 8 61 Removing a wheel 8 62 Installing a wheel 8 63 Troubleshooting 8 64 Troubleshooting charts 8 65 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUM...

Page 11: ... child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Watch carefully for other vehicles when operat ing on unpaved public streets or roads Make sure you know your country s...

Page 12: ...limbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefull...

Page 13: ...anual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tir...

Page 14: ...e gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are poisonous and may cause loss of c...

Page 15: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U3B460E0 book Page 1 Friday May 12 2006 2 51 PM ...

Page 16: ...els contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer For Europe and Oceania U3B460E0 book Page 2 Friday May 12 2006 2 51 PM ...

Page 17: ...2 3 2 For Europe U3B460E0 book Page 3 Friday May 12 2006 2 51 PM ...

Page 18: ...2 4 2 For Europe U3B460E0 book Page 4 Friday May 12 2006 2 51 PM ...

Page 19: ...2 5 2 For Europe U3B460E0 book Page 5 Friday May 12 2006 2 51 PM ...

Page 20: ...2 6 2 For Oceania U3B460E0 book Page 6 Friday May 12 2006 2 51 PM ...

Page 21: ...2 7 2 For Oceania U3B460E0 book Page 7 Friday May 12 2006 2 51 PM ...

Page 22: ...ck 7 Oil filter cartridge 8 Coolant reservoir 1 Rear shock absorber assembly spring preload adjusting ring 2 Rear storage compartment and tool kit 3 Fuel tank cap cover 4 Idle adjusting screw 5 Front shock absorber assembly spring preload adjusting ring 6 Spark plug 7 Brake pedal 8 V belt case drain plug U3B460E0 book Page 1 Tuesday May 16 2006 4 35 PM ...

Page 23: ... 2 Rear brake lever 3 Handlebar switches 4 Horn switch 5 Rear brake fluid reservoir 6 Multifunction meter unit 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 U3B460E0 book Page 2 Friday May 12 2006 2 51 PM ...

Page 24: ...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 U3B460E0 book Page 1 Friday May 12 2006 2 51 PM ...

Page 25: ...ectrical circuit of the warning light can be checked by turning the key to ON If the light does not come on have a Yamaha dealer inspect the electrical circuit CAUTION ECB00010 The engine may overheat if the ATV is over loaded In this case reduce the load to spec ification 1 On Command differential gear lock indicator light DIFF LOCK 2 Low range indicator light L 3 High range indicator light H 4 N...

Page 26: ...ctive When this occurs have a Yamaha deal er check the EPS system The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on have a Yamaha dealer check the electrical circuit NOTE If the engine is stopped using the engine stop switch and the key is in the ON position the EPS warning light comes on to indicate that the power assistance ...

Page 27: ...icator light comes on when the transmis sion is in the high range position EBU17990 Low range indicator light This indicator light comes on when the transmis sion is in the low range position EBU18001 On Command differential gear lock indicator light DIFF LOCK This indicator light and the On Command differen tial gear lock indicator in the display come on when the On Command differential gear lock...

Page 28: ... following 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 NOTE Holding in the SELECT button and then turning the key to ON switches the display...

Page 29: ... 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 NOTE This fuel meter is equipped with a self diagnosis system If the electrical circuit is defective all the display segments and ...

Page 30: ...splay indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage EBU18060 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 th...

Page 31: ...y discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU18170 Horn switch Press the switch to sound the horn EBU18190 Override switch OVERRIDE Top speed is normally limited when operating in differential gear lock If conditions require more en gine power when riding forward push and hold this switch to override the diffe...

Page 32: ...ccident if you cannot make a sharp enough turn for the speed you are trav eling EBU26602 On Command four wheel drive switch 2WD 4WD This ATV is equipped with a switch to change from two wheel drive to four wheel drive and vice versa Select the appropriate drive according to the ter rain and the conditions 2WD two wheel drive Power is supplied to the rear wheels 4WD four wheel drive Power is suppli...

Page 33: ...al gear lock switch 4WD LOCK This ATV is equipped with a switch allowing you to lock the differential gear when in four wheel drive Select the appropriate switch position according to the terrain and the conditions 4WD four wheel drive Power is supplied to the rear and front wheels LOCK four wheel drive with the differential gear locked Power is supplied to the rear and front wheels and the differ...

Page 34: ...ease the differential gear lock stop the ATV and push the switch to the 4WD position WARNING EWB00130 Always stop the ATV before changing from four wheel drive to four wheel drive differen tial gear lock or vice versa The ATV handles differently in four wheel drive than in differential gear lock in some circum stances Changing from four wheel drive to dif ferential gear lock or vice versa while mo...

Page 35: ...ck and forth will help the differential gear lock to engage Riding before the differential gear lock is proper ly engaged e g when the indicator and indica tor light are flashing will cause the engine speed to be limited until engagement is complete When the ATV is in four wheel drive differential gear lock the maximum traveling speed is limit ed to 35 km h 22 mi h However if conditions require fu...

Page 36: ...ct the problem be fore riding the ATV or consult a Yamaha dealer EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum 1 Loosen the locknut 2 To increase the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To...

Page 37: ...ever free play is adjusted to 3 0 5 0 mm 0 12 0 20 in See page 8 43 EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull the brake lever toward the handlebar grip EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar To apply the rear br...

Page 38: ...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 U3B460E0 book Page 15 Friday May 12 2006 2 51 PM ...

Page 39: ...k is heard and then close the fuel tank cap cover EBU18750 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap cover 1 Fuel tank cap 1 Fuel level 2 Fuel tank filler tube U3B460E0 book Page 16 Friday May 12 2006 2 51 PM ...

Page 40: ...eful not to spill fuel especially on the engine or exhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear Recommended fuel UNLEADED GASOLINE ONLY...

Page 41: ... fitted EBU27361 Storage compartments This ATV is equipped with two storage compart ments The front storage compartment is located at the front right side of the ATV To access the storage compartment remove the storage compartment cover by turning it counterclockwise 1 Projection 2 Seat holder 1 Front storage compartment cover U3B460E0 book Page 18 Friday May 12 2006 2 51 PM ...

Page 42: ...cated under the seat See page 4 17 To access the storage com partment remove the storage compartment cover 1 Front storage compartment 1 Rear storage compartment cover 1 Rear storage compartment U3B460E0 book Page 19 Friday May 12 2006 2 51 PM ...

Page 43: ...riate cushion material to prevent damaging the stor age compartments Do not exceed the load limit of 0 5 kg 1 lb for the front storage compartment or 2 0 kg 4 lb for the rear storage compartment Do not exceed the maximum load of 220 0 kg 485 lb for the ATV NOTE A drain plug is fitted at the bottom of each storage compartment If any water collects in a storage compartment remove the drain plug drai...

Page 44: ...ront and rear shock ab sorber assemblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension NOTE A special wrench can be obtained at a Y...

Page 45: ...s located at the front right side of the ATV The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Set the light switch to OFF 2 Start the engine See page 6 1 3 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 1 Special wrench Spring preload setting Minimum soft 1 Standard 2...

Page 46: ...ries are used without the engine running or with the headlights turned on the battery will lose its charge and engine start ing may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged 1 Auxiliary DC jack cap 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A U3B460E0 book Pag...

Page 47: ...mended 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 oil leakage Correct if necessary 5 3 8 26 Differential gear oil Check ATV for oil leakage Correct if necessary 5 3 8 28 Coolant Check coolant level in reservoir and add recommended coolant to specified level if necessary Check cooling system for leakage Correct if necess...

Page 48: ... Make sure that operation is smooth Lubricate cable and lever hous ing if necessary Check cable free play and adjust if necessary 5 5 8 43 Control cables Make sure that operation is smooth Lubricate if necessary 8 51 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 5 5 6 5 7 Brake pedal...

Page 49: ...essary See page 8 22 EBU19590 Final gear oil Make sure that the final gear oil is at the specified level Add oil as necessary See page 8 26 EBU19600 Differential gear oil Make sure that the differential gear oil is at the specified level Add oil as necessary See page 8 28 EBU19630 Coolant Make sure that the coolant is at the specified level Add coolant as necessary See page 8 30 NOTE The coolant l...

Page 50: ...akage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If a lever moves slow ly inward there may be a leak in the brake system If there is any leakage the brake system should be checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the br...

Page 51: ...or this model Other tire combinations are not recommend ed Front Manufacturer model CHENG SHIN C828 4P AUS NZL DUNLOP KT421 EUR Size AT25 x 8 12 Type Tubeless Rear Manufacturer model CHENG SHIN C828 4P AUS NZL DUNLOP KT425 EUR Size AT25 x 10 12 Type Tubeless The tires should be set to the recommended pressure Recommended tire pressure Front 35 0 kPa 5 0 psi 0 350 kgf cm Rear 30 0 kPa 4 3 psi 0 300...

Page 52: ...tire to burst Inflate the tires very slowly and carefully EBU19820 Measuring the tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set the tire pressure when the tires are cold Set the tire pres...

Page 53: ...and switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 35 0 kPa 5 0 psi 0 350 kgf cm Rear 30 0 kPa 4 3 psi 0 300 kgf cm Minimum Front 32 0 kPa 4 6 psi 0 320 kgf cm Rear 27 0 kPa 3 9 psi 0 270 kgf cm Maximum Front 38 0 kPa 5 5 psi 0 380 kgf cm Rear 33 0 kPa 4 8 psi 0 330 kgf cm 1 Tire wear limit U3B460E0 book Page 7 Friday Ma...

Page 54: ... could lead to an acci dent or collision CAUTION ECB00150 See the Engine break in section on page 6 4 prior to operating the engine for the first time 1 Turn the main switch to ON and the engine stop switch to CAUTION ECB00822 The coolant temperature warning light and en gine trouble warning light should come on then go off The EPS warning light should come on then go off when the engine is starte...

Page 55: ...ds before the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt 5 Continue warming up the engine until it idles smoothly CAUTION ECB00160 For maximum engine life always warm the en gine up before starting off Never accelerate hard when the engine is cold NOTE The engine is warm when it responds normally...

Page 56: ...rive select lever cannot be shifted into or from reverse or park without applying the brake pedal 1 Bring the ATV to a complete stop 2 Apply the brake pedal 3 Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park U3B460E0 book Page 3 Friday May 12...

Page 57: ...injury When you shift into reverse make sure there are no people or ob stacles behind you When it is safe to proceed go slowly EBU20681 Engine break in There is never a more important period in the life of your engine than the first 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 20 ...

Page 58: ...lect lever into the park position EBU20820 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 position and then block the fr...

Page 59: ...hich can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limi...

Page 60: ...ee where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trail er Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain...

Page 61: ...arrying or tow ing cargo improperly could cause changes in ATV handling which could lead to an accident Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pulling a trailer Allow greater dis tance for braking U3B460E0 book Page 8 Friday May 12 2006 2 51 PM ...

Page 62: ...7 1 7 EBU21141 RIDING YOUR ATV U3B460E0 book Page 1 Friday May 12 2006 2 51 PM ...

Page 63: ...n to the safety information on pages 1 1 1 4 Please also read all caution and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally f...

Page 64: ...e child This ATV is designed to carry operator and car go only passengers prohibited WARNING EWB01400 Never carry a passenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or y...

Page 65: ...cle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet U3B460E0 book Page 4 Friday May 12 2006 2 51 PM ...

Page 66: ... chances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s performance capability is reduced by the influence of alcohol or drugs WARNING EWB01420 Never consume alcohol or drugs before or while driving this ATV Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding for proper care of the ATV and to ens...

Page 67: ...ARNING EWB01450 Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at speeds too fast for your skills or the conditions in creases your chances of losing control of the ATV which can result in an accident Speed limiter For riders less experienced with this model the throttle lever housing is equipped with a speed lim iter...

Page 68: ...w the instructions in your Own er s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards during op eration otherwise they may contact the rear wheels MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 220 0 kg 485 lb Front carrier 45 0 kg 99 lb Rear carrier 85 0 kg 187 lb Front storage compartment 0 5 kg 1 l...

Page 69: ...into con tact with the rear wheels which could injure you or cause an accident Avoid wheelies and jumping You may lose control of the ATV or overturn WARNING EWB01480 Never attempt stunts such as wheelies or jumps Don t try to show off Modifications WARNING EWB01490 Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be gen ...

Page 70: ...ustible materials to pre vent causing a fire hazard WARNING EWB01500 Do not touch the hot exhaust system Do not park the ATV during or after operation in a place where others might be likely to touch it Do not operate idle or park the ATV in dry grass dry ground cover or combustible ma terials BE CAREFUL WHERE YOU RIDE This ATV is designed for use on unpaved surfaces only Riding on paved surfaces ...

Page 71: ...roads Do not ride on any paved public street road or motorway WARNING EWB01520 Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle In many areas it is illegal to operate ATVs on public streets roads and highways Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden h...

Page 72: ...d practiced the skills necessary to control the ATV on such terrain Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracke...

Page 73: ... practice control of the throttle brakes shifting procedures and turning techniques in this area before trying more difficult terrain Always avoid riding on paved surfaces the ATV is designed for use on unpaved surfaces only and handling maneuvers are more difficult to perform on pavement Shift to the park position and follow the instruction on page 6 1 to start the engine Once it has warmed up yo...

Page 74: ...more when riding in 4WD LOCK DIFF LOCK the front wheels also turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed WARNING EWB01770 Always follow p...

Page 75: ...rn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid ATV over...

Page 76: ...w proper procedures for climb ing hills as described in this Owner s Manu al Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person co...

Page 77: ...led or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose control If you are unable to continue up the hill dismount the ATV on the up hill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply either brake abruptly If you are in 2WD apply only the fro...

Page 78: ...smount on uphill side or to a side if pointed straight uphill Turn the ATV around and re mount following the procedure described in the Owner s Manual RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Engine compression will do most of the braking for you For maximum engin...

Page 79: ... choose your path and ride no faster than you will be able to react to ob stacles which may appear WARNING EWB01620 Always follow proper procedures for going down hills as described in this Owner s Manu al Note a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high ...

Page 80: ...tempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your ...

Page 81: ...loss of control which could lead to an accident Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability CAUTION ECB00840 After riding your ATV in water be sure to drain the trapped water by removing the check hos es at the bottom of the air filter case Also re move the drain plugs from the front and rear storage comp...

Page 82: ...7 21 7 1 Air filter case check hose 1 Air filter case check hose 1 Storage compartment drain plug 1 Storage compartment drain plug U3B460E0 book Page 21 Friday May 12 2006 2 51 PM ...

Page 83: ... for ob stacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manu al SLIDING AND SKIDDING Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front...

Page 84: ...liding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to re duce the chance of skidding or sliding out of control WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding tech niques completely WHAT TO DO If your ATV doesn t turn when you want it to Bring th...

Page 85: ...he uphill side See page 7 14 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 14 If your ATV encounters shal...

Page 86: ...L USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with maintenance w...

Page 87: ...ience required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for use on this ATV and should be insta...

Page 88: ...cal skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1200 750 2400 1500 2400 1500 4800 3000 hours 20 75 150 150 300 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if necessary 4 Air filter element...

Page 89: ... and replace if nec essary 10 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 11 Wheel bearings Check for looseness or damage and replace if necessary 12 Upper and lower arm pivots Lubricate with lithium soap based grease 13 V belt Check for wear cracks or other damage and re place if necessary 14 Drive shaft univer sal joint ...

Page 90: ...ion and repair or replace if damaged Check toe in and adjust if necessary 22 Engine mount Check for cracks or other damage and replace if necessary 23 Axle boots Check for cracks or other damage and replace if necessary 24 Fuel injection Check and adjust engine idle speed 25 Crankcase breather system Check breather hose for cracks or other damage and replace if necessary 26 Engine oil Change Check...

Page 91: ...rottle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 34 Exhaust system Check for leakage and replace gasket s if neces sary Check for looseness and tighten all screw clamps and joints if necessary 35 Spark arrester Clean 36 Front and rear brake switches Check operation and correct...

Page 92: ...onents of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 37 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 320 200 1200 750 2400 1500 2400 1500 4800 3000 hours 20 75 150 150 300 U3B46...

Page 93: ...nce jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU27381 Panel A To remove the panel Pull upward on the areas shown 1 Panel A 2 Panel B 3 Panel C 4 Panel D 5 Panel F 6 Panel G 1 Panel E 2 Panel H 3 Panel I U3B460E0 book Page 8 Friday May 12 2006 2 51 PM ...

Page 94: ...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 U3B460E0 book Page 9 Friday May 12 2006 2 51 PM ...

Page 95: ...arrier stays by removing the bolts 4 Remove the quick fastener screws and then pull the panel upward to remove it 1 Carrier bolt top 1 Front carrier stay 1 Front carrier stay bolt U3B460E0 book Page 10 Friday May 12 2006 2 51 PM ...

Page 96: ...ont carrier stays by installing the bolts and tightening them to the specified torque 3 Install the front carrier by installing the bolts and tightening them to the specified torques 1 Panel B 2 Quick fastener screw Tightening torque Front carrier stay bolt 26 Nm 2 6 m kgf 19 ft lbf U3B460E0 book Page 11 Friday May 12 2006 2 51 PM ...

Page 97: ...ll the panel upward as shown to remove it To install the panel 1 Place the panel in the original position and then install the quick fastener screws Tightening torques Carrier bolt top 26 Nm 2 6 m kgf 19 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Panel C 2 Quick fastener screw U3B460E0 book Page 12 Friday May 12 2006 2 51 PM ...

Page 98: ...1 Remove panel C 2 Remove the quick fastener screw and bolt and then pull the panel upward as shown to remove it NOTE To ease removal of panel D shift the drive select lever into the reverse position 1 Panel D 2 Quick fastener screw 1 Bolt U3B460E0 book Page 13 Friday May 12 2006 2 51 PM ...

Page 99: ... one of the panels 1 Place the panel in the original position and then install the bolt and quick fastener screw 2 Install panel C 1 Panel E 2 Quick fastener screw 1 Bolt U3B460E0 book Page 14 Friday May 12 2006 2 51 PM ...

Page 100: ... areas shown To install the panel Place the panel in the original position Panel G To remove the panel Remove the nut bolts and quick fastener and then pull the panel downward while pushing the tab 1 Panel F U3B460E0 book Page 15 Friday May 12 2006 2 51 PM ...

Page 101: ... and then in stall the bolts nut and quick fastener Panel H To remove the panel Remove the nut bolts and quick fasteners and then pull the panel downward while pushing the tab 1 Panel G 2 Nut 3 Bolt 4 Quick fastener 5 Tab U3B460E0 book Page 16 Friday May 12 2006 2 51 PM ...

Page 102: ...osition and then in stall the bolts nut and quick fasteners Panel I To remove the panel 1 Remove the seat See page 4 17 2 Remove the rear carrier by removing the bolts 1 Panel H 2 Nut 3 Bolt 4 Quick fastener 5 Tab U3B460E0 book Page 17 Friday May 12 2006 2 51 PM ...

Page 103: ...8 18 8 3 Remove the quick fasteners and then push inward on the areas shown 1 Carrier bolt under the fenders 1 Carrier bolt upper 1 Carrier bolt lower U3B460E0 book Page 18 Friday May 12 2006 2 51 PM ...

Page 104: ...ier by installing the bolts and tightening them to the specified torques 3 Install the seat 1 Panel I 2 Quick fastener Tightening torques Carrier bolt upper 48 Nm 4 8 m kgf 35 ft lbf Carrier bolt lower 48 Nm 4 8 m kgf 35 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf U3B460E0 book Page 19 Friday May 12 2006 2 51 PM ...

Page 105: ...park plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally NOTE If the spark plug shows a distinctly different color the engine could be operating ...

Page 106: ...p to specification 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK CR8E Spark plug gap 0 7 0 8 mm 0 028 0 031 in 1 Spark plug gap Tightening torque Spark plug 12 5 Nm 1 25 m kgf 9 0 ft lbf U3B460E0 book ...

Page 107: ...placed 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 NOTE If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least 10 minutes until the oil settles for an accurate reading 3 Remove panel F See...

Page 108: ...CB00850 Be sure the engine oil is at the correct level otherwise engine damage may result To change the engine oil with or without oil fil ter cartridge replacement 1 Place the ATV on a level surface 2 Remove panel F See page 8 8 3 Place an oil pan under the engine to collect the used oil 4 Remove the dipstick and then remove the en gine oil drain bolt to drain the oil from the crankcase 1 Maximum...

Page 109: ...available at a nearby Yamaha dealer 7 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge NOTE Make sure that the O ring is properly seated 8 Install the new oil filter cartridge with an oil fil ter wrench and then tighten it to the specified torque with a torque wrench 1 Oil filter cartridge 2 Oil filter wrench 1 O ring U3B460E0 book Page 24 Friday May 12 2006 2 51 PM ...

Page 110: ...ls with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf Recommended oil See page 10 1 Oil quantity Withou...

Page 111: ... must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oil level must be checked on a cold engine 2 Remove the final gear oil level check bolt and then check the oil level in the final gear case NOTE The oil level should be at the brim of th...

Page 112: ...e final gear oil drain bolt to drain the oil from the final gear case 4 Install the drain bolt and then tighten it to the specified torque 5 Add the recommended final gear oil to the brim of the check hole as shown 1 Final gear oil filler bolt Tightening torques Final gear oil level check bolt 10 Nm 1 0 m kgf 7 2 ft lbf Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil drain bo...

Page 113: ...nd repair the ATV In addition the differential gear oil level must be checked and the oil changed as follows at the in tervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface NOTE The differential gear oil level must be checked on a cold engine 1 Final gear oil 2 Final gear oil level check bolt 3 Correct oil le...

Page 114: ...the differential gear oil 1 Place the ATV on a level surface 2 Place an oil pan under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case 4 Install the drain bolt and then tighten it to the specified torque 1 Differential gear oil 2 Differential gear oil filler bo...

Page 115: ...t level should be checked before each ride In addition the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart EBU27122 To check the coolant level 1 Place the ATV on a level surface Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 Differential gear oil 2 Differential gear oil filler bolt 3 Correct oil level Recommended...

Page 116: ...ant is at or below the minimum level mark remove panel D See page 8 8 4 Remove the reservoir cap add coolant or dis tilled water to the maximum level mark install the reservoir cap and then install the panel 1 Maximum level mark 2 Minimum level mark 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark Coolant reservoir capacity up to the maximum level mark 0 17 L 0 18 US qt 0 15 Imp q...

Page 117: ...matically switched on or off according to the coolant temperature in the radiator If the engine overheats see page 8 65 for fur ther instructions EBU27761 To change the coolant WARNING EWB01890 Wait for the engine and radiator to cool before removing the radiator cap You could be burned by hot fluid and steam blown out under pressure Always place a thick rag over the cap when opening Allow any rem...

Page 118: ...e radiator cap 6 Remove the coolant reservoir cap 7 Disconnect the hose on the coolant reservoir side and then drain the coolant from the cool ant reservoir 1 Coolant drain bolt 1 Trough 1 Radiator cap U3B460E0 book Page 33 Friday May 12 2006 2 51 PM ...

Page 119: ...tap water instead Do not use hard wa ter or salt water since it is harmful to the en gine If water has been used instead of coolant re place it with coolant as soon as possible otherwise the cooling system will not be pro tected against frost and corrosion 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 antifre...

Page 120: ... When coolant begins to flow out of the bolt hole tighten the water pump air bleed bolt to the specified torque 15 Remove panel E See page 8 8 16 Loosen the clamp screw and then remove the V belt cooling duct 17 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 ble...

Page 121: ...ge NOTE If any leakage is found have a Yamaha dealer check the cooling system 24 Install the V belt cooling duct and then tighten the clamp screw 25 Install the panels EBU27800 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusua...

Page 122: ...ects in them empty them and clean the air filter element and air filter case 1 Remove panel C See page 8 8 2 Remove the air filter case cover by unhooking the holders 1 Air filter case check hose 1 Air filter case check hose U3B460E0 book Page 37 Friday May 12 2006 2 51 PM ...

Page 123: ...G EWB01940 Always use parts cleaning solvent to clean the sponge material Never use low flash point solvents or gasoline to clean the sponge mate rial because the engine could catch fire or ex plode 6 Squeeze the excess solvent out of the sponge material and let it dry 1 Air filter case holder 2 Air filter case cover 1 Sponge material 2 Air filter mesh U3B460E0 book Page 38 Friday May 12 2006 2 51...

Page 124: ...e and then install the air filter case cover by hooking the holders onto the cover 11 Install the panel NOTE The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filt...

Page 125: ...njection system with sub sequent poor performance and possible en gine overheating EBU27810 Cleaning the spark arrester Select a well ventilated area free of combustible materials and make sure the exhaust and muffler are cool 1 Remove the bolts 2 Remove the tailpipe by pulling it out of the muffler and then remove the gasket 3 Tap the tailpipe lightly and then use a wire brush to remove any carbo...

Page 126: ...s while momentarily creating ex haust system back pressure by blocking the end of the muffler with a shop towel 8 Stop the engine and allow the exhaust pipe to cool 9 Install the purging bolt and tighten it to the specified torque 1 Tailpipe 2 Spark arrester 3 Gasket Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 Purging bolt Tightening torque Purging bolt 27 Nm 2 7 m kgf 19 ft lbf U...

Page 127: ... plug After riding in water deep enough to allow it to en ter the V belt case remove this plug to drain the water from the case NOTE 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 EBU27310 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the i...

Page 128: ...aha dealer make the adjustment 5 Install the panel EBU24043 Adjusting the throttle cable free play The throttle cable free play should be checked and if necessary adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The throttle cable free play should measure 3 0 5 0 mm 0 12 0 20 in at the throttle lever Period ically check the throttle cable free play and if nec ...

Page 129: ...h es with use which can result in improper function Therefore the safety system cable should be checked and adjusted at the intervals specified in the periodic maintenance and lubrication chart EBU27470 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart Each brake pad is provide...

Page 130: ...tectors must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart Each brake hose protector is provided with a wear indicator If a protector wears to the point that its indicator be comes visible have a Yamaha dealer replace the protector 1 Wear indicator groove 1 Wear indicator groove U3B460E0 book Page 45 Friday May 12 2006 2 51 PM ...

Page 131: ...iding check that the brake fluid is above the minimum level mark and replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Front brake 1 Rear brake hose protector 2 Wear indicator 3 Protector is normal 4 Protector is worn 1 Minimum level mark ...

Page 132: ...d may deteriorate painted surfaces or plastic parts Always clean up spilled fluid imme diately As the brake pads wear it is normal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24290 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the peri o...

Page 133: ...ave a Yamaha dealer check the brake system Front brake Rear brake WARNING EWB02070 Operating with improperly serviced or adjust ed brakes could cause loss of braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake s...

Page 134: ...rform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting the brake pedal free play and checking the brake pedal position check the rear brake pads for wear Adjusting the brake pedal free play The brake pedal free play should measure 0 0 5 0 mm 0 00 0 20 in as shown If the free play is in correct adjust it as follows 1 Remove panel H See page 8 8 2...

Page 135: ...ould be positioned 56 7 mm 2 23 in above the top of the footrest If the brake pedal position is incorrect have a Yamaha dealer adjust it WARNING EWB02070 Operating with improperly serviced or adjust ed brakes could cause loss of braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag 1 ...

Page 136: ...on chart Check the axle boots for tears or damage If any damage is found have them re placed by a Yamaha dealer EBU24900 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it...

Page 137: ...ration of controls and lead to an accident or injury EBU24911 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary Front brake lever Rear brake lever Recommended lubricant Lithium soap based grease all purpose grease U3B460E0 book Page 52 Friday May 12 2006...

Page 138: ... does not turn smoothly have a Yamaha dealer check the wheel bearings EBU24980 Lubricating the drive shaft universal joint The drive shaft universal joint must be lubricated at the intervals specified in the periodic maintenance and lubrication chart EBU25021 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic mainten...

Page 139: ... pivoting points using a grease gun EBU25080 Lubricating the knuckle shafts The knuckle shafts must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart EBU25100 Lubricating the steering shaft The steering shaft must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart Recommended lubricant Lithium soap based grease Re...

Page 140: ...mmediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the ba...

Page 141: ...spe cial constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a constant voltage battery charg er have a Yamaha dealer charge your bat tery EBU27750 Replacing a fuse 1 Positive battery terminal 2 Negative battery terminal 1 Fuse box 2 Main EPS spare fuse 3 Main fuse 4 EPS fuse 5 Fuel injection system spare fuse 6 Fu...

Page 142: ...lectrical circuits CAUTION ECB00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Ignition fuse 2 Headlight fuse 3 Four wheel drive motor fuse 4 Radiator fan fuse 5 Signaling system fuse 6 Auxiliary DC jack fuse 7 Spare fuse U3B460E0 book Page 57 Friday May 12 2006 2 ...

Page 143: ...If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU27440 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off Specified fuses Main fuse 40 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A Signaling system fuse 5 0 A Auxiliary DC jack fuse...

Page 144: ...over 3 Disconnect the headlight coupler 4 Unhook the headlight bulb holder and then remove the defective bulb 1 Cover at the rear of the headlight 1 Headlight bulb cover 1 Headlight coupler U3B460E0 book Page 59 Friday May 12 2006 2 51 PM ...

Page 145: ... touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affect ed Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth moistened with alcohol or thinner 6 Connect the headlight coupler 7 Install the headlight bulb cover 8 Install the cover at the rear o...

Page 146: ...ealer make this adjustment To raise a headlight beam turn the adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25640 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove panel I See page 8 8 2 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Headlight beam adjusting...

Page 147: ...ops 5 Install the bulb holder together with the bulb by turning it clockwise 6 Install the panel EBU25650 Removing a wheel 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Tail brake light bulb holder 1 Tail brake light bulb 1 Wheel nut U3B460E0 book Page 62 Friday May 12 2006 2 51 PM ...

Page 148: ...uts are used for both the front and rear wheels Install the nuts with their tapered side to wards the wheel 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U3B460E0 book Page 63 Friday May 12 2006 2 51 PM ...

Page 149: ...any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite o...

Page 150: ...aler check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly Th...

Page 151: ...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 NOTE Start the engine If the engine overheat...

Page 152: ...terioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach place...

Page 153: ...Long term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing 3 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the sp...

Page 154: ... wheels a little every month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation...

Page 155: ... 648 lb Noise and vibration level Noise level 77 311 EEC 78 8 dB A EUR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s EUR Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s EUR Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 686 0 cm Bore stroke 102 0 84 0 mm 4 02 3 31 in Compression ratio 9 20 1 Starting system...

Page 156: ... 23 US qt 0 19 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 17 L 0 18 US qt 0 15 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 EUR Unleaded gasoline only AUS NZL Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount 4 5 L 1...

Page 157: ... Front tire Type Tubeless Size AT25 x 8 12 Manufacturer model CHENG SHIN C828 4P AUS NZL DUNLOP KT421 EUR Rear tire Type Tubeless Size AT25 x 10 12 Manufacturer model CHENG SHIN C828 4P AUS NZL DUNLOP KT425 EUR Loading Maximum loading limit 220 0 kg 485 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 35 0 kPa 5 0 psi 0 350 kgf cm Rea...

Page 158: ...wishbone Spring shock absorber type Coil spring oil damper Wheel travel 180 mm 7 1 in Rear suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 230 mm 9 1 in Electrical system Ignition system Transistorized coil ignition digital Charging system AC magneto Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wa...

Page 159: ...ock indicator LCD High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Fuses Main fuse 40 0 A Fuel injection system fuse 15 0 A EPS fuse 40 0 A Headlight fuse 15 0 A Signaling system fuse 5 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 15 0 A Four wheel drive motor fuse 10 0 A Radiator fan fuse 15 0 A U3B460E0 book Page 5 Friday May 12 2006 2 51...

Page 160: ...f erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26040 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key i...

Page 161: ...V 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 Yamaha deal er 1 Vehicle identification number front left side 1 Vehicle identification number 2 Year of manufacture U3B460E0 book Page 2 Friday May 12 2006 2 51 PM ...

Page 162: ...11 3 11 1 Model label U3B460E0 book Page 3 Friday May 12 2006 2 51 PM ...

Page 163: ...oolant temperature warning light 4 2 D Differential gear lock indicator light 4 4 Differential gear oil 5 3 8 28 Drive select lever 4 15 Drive select lever and driving in reverse 6 2 Drive select lever safety system cable adjusting 8 44 Drive shaft universal joint lubricating 8 53 E Engine break in 6 4 Engine idling speed 8 42 Engine oil 5 3 Engine oil and oil filter cartridge 8 22 Engine stop swi...

Page 164: ... operation check list 5 1 R Reverse indicator light 4 2 Riding your ATV 7 1 S Safety information 1 1 Seat 4 17 Shock absorber assemblies adjusting the front and rear 4 21 Spark arrester cleaning 8 40 Spark plug checking 8 20 Specifications 10 1 Speed limiter 4 13 Stabilizer bushes checking 8 53 Starting the engine 6 1 Start switch 4 8 Steering shaft lubricating 8 54 Storage 9 2 Storage compartment...

Page 165: ...Wheel installing 8 63 Wheel removing 8 62 U3B460E0 book Page 3 Friday May 12 2006 2 51 PM ...

Page 166: ...YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006 05 1 4 1 CR E U3B460E0 book Page 1 Friday May 12 2006 2 51 PM ...

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