Yamaha Grizzly 700 FI Owner'S Manual Download Page 123

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2. Remove the differential gear oil filler bolt, and

then check the oil level in the differential gear
case.

TIP

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 of the recommended type to raise
it to the correct level.

4. Install the oil filler bolt, and then tighten it to the

specified torque.

To change the differential gear oil

1. Place the ATV on a level surface.
2. Place an oil pan under the differential gear

case to collect the used oil.

3. Remove the differential gear oil filler bolt 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 bolt

3. Correct oil level

Tightening torque:

Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

1. Differential gear oil drain bolt

U43P10E0.book Page 30 Thursday, May 15, 2008 2:55 PM

Summary of Contents for Grizzly 700 FI

Page 1: ...This ATV should not be ridden by anyone under 16 years of age WARNING OWNER S MANUAL 43P 28199 10 LIT 11626 22 42 YFM7FGPY READ THIS MANUAL CAREFULLY It contains important safety information DIC2342 ...

Page 2: ...EBU17092 Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold U43P10E0 book Page 1 Thursday May 15 2008 2 55 PM ...

Page 3: ...special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIO...

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

Page 5: ... and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17382 YFM7FGPY OWNER S MANUAL 2008 by Yamaha Motor Corporation U S A 1st edition April 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Print...

Page 6: ...tle lever 4 13 Speed limiter 4 14 Front brake lever 4 15 Brake pedal and rear brake lever 4 15 Drive select lever 4 16 Fuel tank cap 4 16 Fuel 4 17 Seat 4 19 Storage compartments 4 19 Front carrier 4 22 Rear carrier 4 22 Adjusting the front and rear shock absorber assemblies 4 22 Auxiliary DC jack 4 23 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 4 Engine oil 5 4 Final gear oil 5 4...

Page 7: ...OR REPAIR 8 1 Owner s manual and tool kit 8 1 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 4 Removing and installing panels 8 8 Removing the radiator grills 8 20 Checking the spark plug 8 20 Engine oil and oil filter cartridge 8 22 Final gear oil 8 27 Differential gear oil 8 29 Coolant 8 31 Cleaning the air filter element 8 37 Cleaning ...

Page 8: ...ricating the steering shaft 8 55 Battery 8 55 Replacing a fuse 8 58 Replacing a headlight bulb 8 60 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 67 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise re...

Page 9: ...hould never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Neve...

Page 10: ...imbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully...

Page 11: ... fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size...

Page 12: ...the ATV in another vehi cle be sure it is kept upright Otherwise fuel may leak out of the fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause inju ries HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some gas oline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and water If gasoline spills on...

Page 13: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U43P10E0 book Page 1 Thursday May 15 2008 2 55 PM ...

Page 14: ...nd proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer 99 lbs 45 kg 3B4 24875 U0 187 lbs 85 kg 3B4 24875 S0 43P 2151K 00 5880 N 600 kgf 1322 lbf 147 N 15 kgf 33 lbf U43P10E0 book Page 2 Thursday May 15 2008 2 55 PM ...

Page 15: ...ver set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING TRAILER TOWING Cargo or a trailer can affect stability and handling Read owner s manual before loading or towing When loading with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Maximum weight capacity 485 lbs 220 kg Includes weight of operator cargo and ac...

Page 16: ...2816L 00 NEVER operate this ATV if you are under age 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death 16 UNDER 8 9 10 U43P10E0 book Page 4 Thursday May 15 2008 2 55 PM ...

Page 17: ... oil dipstick 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 Front shock absorber assembly spring preload adjusting ring 5 Spark plug 6 Brake pedal 7 V belt case drain plug U43P10E0 book Page 1 Thursday May 15 2008 2 55 PM ...

Page 18: ...ct lever 2 Rear brake lever 3 Handlebar switches 4 Rear brake fluid reservoir 5 Multifunction display 6 Front brake fluid reservoir 7 On Command four wheel drive differential gear lock switch 8 Front brake lever 9 Throttle lever 10 Front storage compartment 11 Main switch 12 Auxiliary DC jack U43P10E0 book Page 2 Thursday May 15 2008 2 55 PM ...

Page 19: ...in switch The positions of the main switch are as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U43P10E0 book Page 1 Thursday May 15 2008 2 55 PM ...

Page 20: ...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 NOTICE ECB00891 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 ligh...

Page 21: ...rning light comes on when the key is turned to ON and then goes off once the engine is start ed If the warning light remains on or comes on af ter the engine is started the EPS system may be defective 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 dea...

Page 22: ...es on when the transmis sion is in the park position EBU17980 High range indicator light This indicator 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 di...

Page 23: ...DO 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 key to ON while the button is pushed switc...

Page 24: ... 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 electrical circuit is defective all the display segments and f...

Page 25: ...ion display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage EBU18061 Handlebar switches EBU18080 Engine stop switch Set this switch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run w...

Page 26: ... oth erwise the battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU18180 Override switch OVERRIDE Top speed is normally limited when operating in differential gear lock If conditions require more en gine power when riding forward push and hold this switch to override the differential gear lock speed limiti...

Page 27: ... is supplied to the rear wheels 4WD four wheel drive Power is supplied to the rear and front wheels POTENTIAL HAZARD Riding too fast while the ATV is in four wheel drive differential gear lock WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the ATV The effort needed to turn in creases with the riding speed You may lose control and h...

Page 28: ...ve Power is supplied to the rear and front wheels 1 On Command four wheel drive switch 2WD 4WD POTENTIAL HAZARD Changing from two wheel drive to four wheel drive or from four wheel drive to two wheel drive while the ATV is moving 2WD 4WD 1 WHAT CAN HAPPEN The ATV handles differently in two wheel drive than in four wheel drive in some cir cumstances Changing from two wheel drive to four wheel drive...

Page 29: ...op the ATV move the differential gear lock lever to position a and then push the differential gear lock switch in to the LOCK position When the dif ferential gear is locked the differential gear lock in dicator light DIFF LOCK will come on along with the indicator in the multifunction display 1 On Command four wheel drive switch 2WD 4WD 2 On Command differential gear lock switch 4WD LOCK 2WD 4WD 1...

Page 30: ...y cause the ATV to handle differently unexpectedly This could distract the operator and increase the risk of losing control and causing an accident HOW TO AVOID THE HAZARD Always stop the ATV before changing from four wheel drive to four wheel drive differen tial gear lock or vice versa POTENTIAL HAZARD Riding too fast while the ATV is in four wheel drive differential gear lock WHAT CAN HAPPEN All...

Page 31: ...able push and hold the override switch to disable the differ ential gear lock speed limiter See page 4 8 for a detailed explanation of this switch EBU18270 Throttle lever Once the engine is running movement of the throt tle lever 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...

Page 32: ... b 3 Tighten the locknut WARNING EWB00190 POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate mak ing it difficult to speed up or slow down when you need to This could cause an acci dent HOW TO AVOID THE HAZARD Check the operation of the throttle lever be fore you start the engine If it does not work smoothly check for the cause Correct the problem before...

Page 33: ...ndlebar To apply the rear brake push down on the brake pedal or pull the brake lever toward the handlebar grip WHAT CAN HAPPEN The throttle cable could be damaged Im proper throttle operation could result You could lose control have an accident or be in jured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjuste...

Page 34: ...erating the drive select lever and driving in reverse section on page 6 3 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 U43P10E0 book Page 16 Thursday May 15 2008 2 55 PM ...

Page 35: ... is heard and then close the fuel tank cap cover EBU18730 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 U43P10E0 book Page 17 Thursday May 15 2008 2 55 PM ...

Page 36: ...nt does not exceed 10 Gasohol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ATV performance problems WARNING EWB00270 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can...

Page 37: ... at the rear TIP Make sure that the seat is securely 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 Seat 2 Seat lock lever 1 Projection 2 Seat holder U43P10E0 book Page 19 Thursd...

Page 38: ... under the seat See page 4 19 To access the storage com partment remove the storage compartment cover 1 Front storage compartment cover 1 Front storage compartment 1 Rear storage compartment cover U43P10E0 book Page 20 Thursday May 15 2008 2 55 PM ...

Page 39: ...opriate 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 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 dra...

Page 40: ...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 Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension 1 Storage comp...

Page 41: ...switch to OFF 2 Start the engine See page 6 1 3 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 1 Special wrench Spring preload setting Minimum soft 1 Standard 3 Maximum hard 5 POTENTIAL HAZARD Improper shock absorber assembly adjust ment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVO...

Page 42: ...h the headlights turned on the battery will lose its charge and engine start ing may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death 1 Auxiliary DC jack cap 1 Auxiliary DC jack Maximum rated capacity for the auxiliary ...

Page 43: ...L HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual ITEM ROUTINE P...

Page 44: ...cessary 5 5 8 45 8 47 8 48 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check pedal free play and adjust if necessary Check brake pads for wear and replace if necessary Check brake fluid level in reservoir and add recommended brake fluid to specified level if necessary Check hydraulic system for leakage Correct if necessary 5 5 8 45 8 47 8 48 8 49 Throttl...

Page 45: ... 53 Axle boots Check for cracks or damage and replace if necessary 8 51 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 9 Instruments lights and switches Check operation and correct if necessary 5 9 ITEM ROUTINE PAGE U43P10E0 book Page 3 Thursday May 15 2008 2 55 PM ...

Page 46: ...IP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture WARNING EWB00490 POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill ...

Page 47: ...e 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 brakes do not provide proper bra...

Page 48: ...b lem with the brakes If a problem cannot be corrected by the adjustment procedures pro vided in this manual have a Yamaha dealer check for the cause POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or opera tion of this ATV with improper or uneven tire pressure may cause loss of control in creasing y...

Page 49: ...res must be equal on both sides Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions 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 Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm ...

Page 50: ...re pressure when the tires are cold Set the tire pressures to the following specifications EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm 0 12 in 1 Low pressure tire gauge Recommended pressure Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi U43P10E0 book Page 8 Th...

Page 51: ... all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary 1 Tire wear limit U43P10E0 book Page 9 Thursday May 15 2008 2 55 PM ...

Page 52: ...ATV without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an acci dent or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer POTENTIAL HAZARD Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or ...

Page 53: ...e select lever is in the neutral or park po sition The rear brake lever or brake pedal is applied with the drive select lever in any position How ever it is recommended to shift into the neutral or park position before starting the engine 3 Apply the rear brake lever or brake pedal 4 Completely close the throttle lever and start the engine by pushing the start switch TIP If the engine fails to sta...

Page 54: ...rive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted into position 3 Release the brake pedal and then open the throttle lever gradually Shifting Neutral to Reverse and Reverse to Park TIP The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal 1 Bring the ATV to a complete stop 1 Drive select lever 2 ...

Page 55: ...he brake pedal 5 Open the throttle lever gradually and continue to watch to the rear while backing WARNING EWB00660 EBU20682 Engine break in TIP For ATVs equipped with an odometer or an hour meter follow the figures given in km mi or the figures given in hours 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park POTENTIAL HAZARD Improperly operating in reverse WHAT CA...

Page 56: ...0 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 160 320 km 100 200 mi or 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine freely but do not use full throttle at any time 320 km 200 mi or 20 hours and beyond The ATV can now be operated normally NOTICE ECB00220 If any engine trouble should ...

Page 57: ... Choose a genuine Yamaha ac cessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which 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 ob...

Page 58: ...aded 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 tongue at hitch height Ad just the load in the trailer if necessary to reduce MAXIMUM LOADING LIMIT ATV loading limit total weight of rider cargo accessories and tongue 220 0 kg 485 lb Front carrier 45 0 kg 99 lb Rear carri...

Page 59: ... 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 Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING EWB00750 WARNING EWB00010 Indicates a potential hazard that could result...

Page 60: ...7 1 7 EBU21131 RIDING YOUR ATV U43P10E0 book Page 1 Thursday May 15 2008 2 55 PM ...

Page 61: ...rough practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable ac tivity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this ...

Page 62: ...children under 16 years of age WARNING EWB00901 POTENTIAL HAZARD Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course...

Page 63: ...s that are not recom mended for their age can lead to severe inju ry or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc U43P10E0 book Page 4 Thursday May 15 2008 2 55 PM ...

Page 64: ...N HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as need ed during operation It is not for carrying passengers U43P10E0 book Page 5 Thursday May 15 2008 2 55 PM ...

Page 65: ...e protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or j...

Page 66: ...ould cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always i...

Page 67: ...oss of control in creasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this ATV on page 5 6 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 7 POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control o...

Page 68: ...and accessories Use extra caution when riding the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Re duce your speed when adding additional loads 1 Adjusting screw 1 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 comp...

Page 69: ...ccident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer U43P10E0 book Page 10 Thursday May 15 2008 2 55 PM ...

Page 70: ...r could cause you to lose your balance and fall off of the ATV If you remove a foot from a foot board your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CA...

Page 71: ...me situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nents designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer U43P10E0 book Page 12 T...

Page 72: ...accumulated around the engine area could catch fire Someone touching the exhaust system dur ing or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely...

Page 73: ...walks driveways parking lots and streets POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways U43P10E0 book Page 14 Thursday May 15 2008...

Page 74: ...en rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Cou...

Page 75: ...on excessively rough slip pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain U43P10E0 book Page 16 Thursday May 15 2008 2 55 PM ...

Page 76: ...e sure that this area is free of obstacles and other riders You should practice control of the throttle brakes shifting procedures and turning techniques in this area before trying more difficult terrain Always avoid riding on paved POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be in jured HOW TO AVO...

Page 77: ...rottle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds un til you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly Im...

Page 78: ...s you do so put your weight on the footboard to the out side of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control ...

Page 79: ...perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the ou...

Page 80: ...eep hills WHAT CAN HAPPEN The ATV can overturn more easily on ex tremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO...

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Page 82: ...de Physically turn the ATV around and then descend the hill POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD 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 turn ing on ...

Page 83: ... rolling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Shift to the park position after you are stopped If you begin rolling backwards Keep weight uphill 2WD Never apply the rear b...

Page 84: ...dal will brake the wheels on the down hill side Avoid sudden application of either the front or rear brake because the wheels on the up hill 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 ab...

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Page 86: ...dually 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 WARNING EWB01141 POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you...

Page 87: ...7 28 7 U43P10E0 book Page 28 Thursday May 15 2008 2 55 PM ...

Page 88: ...de your ATV without verifying that you have regained proper braking ability POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember tha...

Page 89: ...ilter case Also re move the drain plugs from the front and rear storage compartments and the V belt case to drain any water that may have accumulated Wash the ATV with fresh water if it has been operated in salt water or muddy conditions 1 Air filter case check hose 1 Air filter case check hose U43P10E0 book Page 30 Thursday May 15 2008 2 55 PM ...

Page 90: ...t or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult WARNING EWB01160 1 Storage compartment drain plug 1 Storage compartment drain plug 1 V belt case drain plug POTENTIAL HAZARD Improperly operating over obstacles U43P10E0 book Page 31 Thursday May 15 2008 2 55 PM ...

Page 91: ...ions positioning your weight over the front wheels will sometimes help WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for ob stacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owne...

Page 92: ...d on extremely slippery surfaces such as ice since all control may be lost WARNING EWB01170 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 POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW...

Page 93: ...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 21 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 th...

Page 94: ...IDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01820 EBU27100 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 POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catc...

Page 95: ...w pressure tire gauge 3 Owner s tool kit POTENTIAL HAZARD Operating this ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added ...

Page 96: ...and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if necessary 4 Crankcas...

Page 97: ...henever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake pedal free play and adjust if neces sary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 4 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years 5 Rear brake hose protectors Check for wear cracks or othe...

Page 98: ...e with lithium soap based grease 14 Steering shaft Lubricate with lithium soap based grease 15 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 16 Engine mount Check for cracks or other damage and replace if necessary 17 Axle boots Check for cracks or other damage and replace if necessary 18 Engine oil Change Check ATV for oil leakage and correc...

Page 99: ...nd adjust or replace if neces sary 25 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 26 Front and rear brake switches Check operation and correct if necessary 27 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANC...

Page 100: ...aulic 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 U43P10E0 book Page 7 Thursday May 15 2008 2 55 PM ...

Page 101: ...nd installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed 1 Panel A 2 Panel B 3 Panel C 4 Panel D 5 Panel F 6 Panel G 1 2 3 5 6 4 U43P10E0 book Page 8 Thursday May 15 2008 2 55 PM ...

Page 102: ... Panel A To remove the panel Pull upward on the areas shown To install the panel Place the panel in the original position 1 Panel E 2 Panel H 3 Panel I 1 3 2 1 Panel A U43P10E0 book Page 9 Friday May 16 2008 9 32 AM ...

Page 103: ...move panel A 2 Remove the front carrier by removing the bolts 3 Remove the front carrier stays by removing the bolts 1 Carrier bolt under the fenders 1 Carrier bolt top 1 Front carrier stay U43P10E0 book Page 10 Thursday May 15 2008 2 55 PM ...

Page 104: ...hen pull the panel upward to remove it To install the panel 1 Place the panel in the original position and then install the quick fasteners 1 Front carrier stay bolt 1 Panel B 2 Quick fastener U43P10E0 book Page 11 Thursday May 15 2008 2 55 PM ...

Page 105: ...Install panel A Panel C To remove the panel 1 Remove the seat See page 4 19 2 Remove panel A 3 Remove the quick fastener screws and then pull the panel upward to remove it Tightening torque Front carrier stay bolt 34 Nm 3 4 m kgf 24 ft lbf Tightening torques Carrier bolt top 26 Nm 2 6 m kgf 19 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf U43P10E0 book Page 12 Thursday May 15 200...

Page 106: ... Install the seat Panels D and E To remove one of the panels 1 Remove panel C 2 Remove the quick fastener screw and bolt and then pull the panel upward to remove it TIP To ease removal of panel D shift the drive select lever into the reverse position 1 Panel C 2 Quick fastener screw U43P10E0 book Page 13 Thursday May 15 2008 2 55 PM ...

Page 107: ...8 14 8 1 Panel D 2 Quick fastener screw 1 Bolt 1 Panel E 2 Quick fastener screw 1 Bolt U43P10E0 book Page 14 Thursday May 15 2008 2 55 PM ...

Page 108: ...ginal position and then install the bolt and quick fastener screw 2 Install panel C Panel F To remove the panel Pull outward on the areas shown To install the panel Place the panel in the original position 1 Panel F U43P10E0 book Page 15 Thursday May 15 2008 2 55 PM ...

Page 109: ...ls G and H To remove one of the panels Remove the nut and bolts and then pull the panel downward while pushing the projection 1 Panel G 2 Nut 3 Bolt 4 Projection U43P10E0 book Page 16 Thursday May 15 2008 2 55 PM ...

Page 110: ...panels Place the panel in the original position and then in stall the bolts and nut Panel I To remove the panel 1 Remove the seat See page 4 19 1 Panel H 2 Nut 3 Bolt 4 Projection U43P10E0 book Page 17 Thursday May 15 2008 2 55 PM ...

Page 111: ... carrier by removing the bolts 3 Remove the quick fasteners and then push inward on the areas shown 1 Carrier bolt under the fenders 1 Carrier bolt upper 1 Carrier bolt lower U43P10E0 book Page 18 Thursday May 15 2008 2 55 PM ...

Page 112: ...er by installing the bolts and tightening them to the specified torques 3 Install the seat 1 Panel I 2 Quick fastener Tightening torques Carrier bolt upper 53 Nm 5 3 m kgf 38 ft lbf Carrier bolt lower 53 Nm 5 3 m kgf 38 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf U43P10E0 book Page 19 Thursday May 15 2008 2 55 PM ...

Page 113: ...ick fastener EBU23211 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark p...

Page 114: ... color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spark plug ...

Page 115: ...Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the intervals spec ified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking...

Page 116: ... engine oil should be between the minimum and maximum level marks 6 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level 7 Insert the dipstick completely into the oil filler hole 8 Install the panel 1 Dipstick 1 Maximum level mark 2 Minimum level mark U43P10E0 book Page 23 Thursday May 15 2008 2 55 PM ...

Page 117: ...e the dipstick and then remove the en gine oil drain bolt to drain the oil from the crankcase TIP Skip steps 5 9 if the oil filter cartridge is not being replaced 5 Remove panel G See page 8 8 6 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer 7 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge 1 E...

Page 118: ...he specified torque with a torque wrench 9 Install panel G 10 Install the engine oil drain bolt and then tight en it to the specified 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 U43P10E0 book Page 25 Thursday May 15 2008 2 55 PM ...

Page 119: ...o not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 12 Start the engine and then let it idle for several minutes while checking it 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 pan...

Page 120: ...r oil level 1 Place the ATV on a level surface TIP 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 TIP The oil level should be at the brim of the check hole 3 If the oil is below the brim of the check hole remove the final gear oil filler bolt and then add sufficient oil of the recommended ty...

Page 121: ...al 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 Refill with 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...

Page 122: ...d 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 TIP 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 leve...

Page 123: ...he 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 bol...

Page 124: ...lant 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 EBU27123 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 Recommen...

Page 125: ... at or below the minimum level mark remove panel D See page 8 8 4 Remove the coolant reservoir cap add cool ant or distilled water to the maximum level mark install the reservoir cap and then install the panel 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 24 L 0 25 US qt 0 21 Imp...

Page 126: ...t temperature in the radiator If the engine overheats see page 8 67 for fur ther instructions EBU27553 To change the coolant WARNING EWB01880 1 Place the ATV on a level surface 2 Remove panels D and F See page 8 8 3 Place a container under the engine and then remove the coolant drain bolt Use a trough or a similar object as shown to prevent coolant from spilling on the engine guard POTENTIAL HAZAR...

Page 127: ... 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 U43P10E0 book Page 34 Thursday May 15 2008 2 55 PM ...

Page 128: ...p 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 antifreez...

Page 129: ...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 blee...

Page 130: ...y 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 EBU27455 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 or if necessary replace the air filter element more frequently if you are ridin...

Page 131: ... 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 9 3 Remove the air filter case cover by unhooking the holders 1 Air filter case check hose 1 Air filter case check hose U43P10E0 book Page 38 Thursday May 15 2008 2 55 PM ...

Page 132: ... gently but thor oughly in solvent WARNING EWB01900 1 Air filter case cover holder 2 Air filter case cover 1 Sponge material 2 Air filter mesh POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode U43P10E0 book Page 39 Thursday May 15 2008 2 55 PM ...

Page 133: ...rial TIP The sponge material should be wet but not drip ping 10 Install the mesh and the sponge material into the air filter case 11 Insert the projections on the air filter case cov er into the holders on the air filter case and then install the air filter case cover by hooking the holders onto the cover 12 Place the hoses in their original position as shown HOW TO AVOID THE HAZARD Use parts clea...

Page 134: ...of unfiltered air en tering the engine NOTICE ECB00760 Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the air filter element will affect the fuel injection system with ...

Page 135: ...er portion of the tailpipe and inside of the tailpipe housing 4 Install the gasket and then insert the tailpipe into the muffler and align the bolt holes 5 Install the bolts and tighten them to the speci fied torque 6 Remove the purging bolt 1 Bolt 1 Tailpipe 2 Spark arrester 3 Gasket Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf U43P10E0 book Page 42 Thursday May 15 2008 2 55 PM ...

Page 136: ...water from the case 1 Purging bolt Tightening torque Purging bolt 27 Nm 2 7 m kgf 19 ft lbf POTENTIAL HAZARD Improperly purging the exhaust system Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When purging the exhaust system Always let the exhaust system cool prio...

Page 137: ...hould 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 essary adjust it as follows TIP The engine idling speed must be checked and ad justed if necessary before adjusting the throttle ca ble free play 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle cable free play turn the throttle cable free play adjust...

Page 138: ...a Yamaha dealer 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 provided with a wear indicator groove which al lows you to check the brake pad wear without hav ing to disas...

Page 139: ...ntenance and lubrication chart Each brake hose protector is provided with a wear indicator If a protector wears to the point that its indicator be comes visible have a Yamaha dealer replace the protector TIP The wheels need to be removed to check the brake hose protectors See page 8 64 1 Wear indicator groove 1 Wear indicator groove U43P10E0 book Page 46 Thursday May 15 2008 2 55 PM ...

Page 140: ... and replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Front brake Rear brake 1 Rear brake hose protector 2 Wear indicator 3 Protector is normal 4 Protector is worn 1 Minimum level mark 1 Minimum level mark 2WD 4WD 1 U43P10E0 book Page 47 ...

Page 141: ...level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24291 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart In addition have the oil seals of the master cylinders and cali pers as well as the brake hoses replaced at the in ...

Page 142: ...ly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that there is no free play Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge Thes...

Page 143: ...y is in correct adjust it as follows 1 Remove panel H See page 8 8 2 Loosen the locknut 3 Turn the brake pedal free play adjusting nut in direction a to increase the free play and in direction b to decrease it 4 Tighten the locknut 5 After adjusting there should be slight play at the brake pedal cable joint as shown If there is no play repeat steps 2 to 4 1 Brake pedal free play 1 Locknut 2 Brake ...

Page 144: ...f any damage is found have them re placed by a Yamaha dealer 1 Brake pedal cable joint 2 Slight play 1 2 POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag...

Page 145: ...eplace it WARNING EWB02120 1 Front axle boot each side 1 Rear axle boot each side 1 1 1 1 Recommended lubricant Engine oil POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cables can also be come frayed or kinked which could restrict the operation of controls and lead to an acci dent or injury HOW TO AVOID THE HAZARD Inspect cab...

Page 146: ...ry Front brake lever Rear brake lever EBU28832 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel H See page 8 8 Recommended lubricant Silicone grease Recommended lubricant Lithium soap based grease U43P10E0 book Page 53 Thursday May 15 20...

Page 147: ...ushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bush es if necessary EBU25051 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the pivoting point...

Page 148: ...ended lubricant Lithium soap based grease POTENTIAL HAZARD Failure to handle batteries or battery electro lyte carefully WHAT CAN HAPPEN You could be poisoned You could be se verely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gas es HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach ...

Page 149: ...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 battery tends to discharge more quickly if the ATV is equipped with optional electri cal accessories 1 Panel A 2 Bolt 1 2 2 1 Battery holding plate 2 Nut 3 Negative battery lead black 4 Positive battery lead red 1 2 4 3 U43P10E0 book Page 56 Thursday May 15 2008 2 ...

Page 150: ...be stored for more than two months check it at least once a month and fully charge it if necessary To install the battery TIP Be sure the battery is fully charged 1 Place the battery in its compartment 2 Connect the positive battery lead first then connect the negative battery lead by installing their bolt 3 Install the battery holding plate by installing the nuts 4 Install the front carrier by in...

Page 151: ...follows 1 Turn the key to OFF and turn off all electrical circuits 1 Fuse box 2 Main EPS spare fuse 3 Main fuse 4 EPS fuse 5 Fuel injection system spare fuse 6 Fuel injection system fuse 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 U43P10E0 book Page 58 Thursday May 15 2008 2 55 PM ...

Page 152: ...f the specified amperage WARNING EWB02151 Specified fuses Main fuse 40 0 A Headlight fuse 15 0 A Ignition fuse 15 0 A Four wheel drive motor fuse 15 0 A Signaling system fuse 5 0 A Auxiliary DC jack fuse 15 0 A Radiator fan fuse 20 0 A Fuel injection system fuse 15 0 A EPS fuse 40 0 A POTENTIAL HAZARD Using an improper fuse U43P10E0 book Page 59 Thursday May 15 2008 2 55 PM ...

Page 153: ...lows 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 WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material in place of the proper fuse 1 Cover at the rear of the headlight 1 Head...

Page 154: ...2 Headlight bulb POTENTIAL HAZARD A headlight bulb is hot when it is on and im mediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it U43P10E0 book Page 61 Thursday May 15 2008 2 55 PM ...

Page 155: ...ct the headlight coupler 7 Install the headlight bulb cover 8 Install the cover at the rear of the headlight NOTICE ECB00670 Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 9 Adjust the headlight beam if necessary EBU25551 Adjusting a headlight beam NOTICE ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headligh...

Page 156: ...ove panel I See page 8 8 2 Remove the bulb holder together with the bulb by turning it counterclockwise 3 Remove the defective 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 U43P10E0 book Page 63 Thursday May 15 2008 2 55 PM ...

Page 157: ...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 158: ...TV re quire 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 EWB02260 1 Tapered nut Tightening torques Front wheel nut...

Page 159: ...ID THE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces U43P10E0 book Page 66 Thursday May 15 2008 2 55 PM ...

Page 160: ...ler check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The...

Page 161: ... engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap 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...

Page 162: ...ansmission 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 places 5 Rinse the ATV off immediately with ...

Page 163: ... 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 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 severa...

Page 164: ...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 165: ... 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 Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 5W 30 or 10W 40 or 20W 50 SAE 5W 30 or SAE 10W 40 or SAE 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA 0 10 30 50 70 90 110 130 F YAMALUBE 4 10...

Page 166: ...Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal Fuel injection Throttle body Type quantity 44EIS 1 Manufacturer MIKUNI Spark plug s Manufacturer model NGK LMAR6A 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch Clutch type Wet centrifugal automatic Tr...

Page 167: ...ressure measured on cold tires Recommended Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi Front wheel Wheel type Panel wheel Rim size 12 x 6 0AT Rear wheel Wheel type Panel wheel Rim size 12 x 7 5AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake...

Page 168: ...alogen bulb Bulb voltage wattage quantity Headlight 12 V 35 0 35 0 W 2 Tail brake light 12 V 5 0 21 0 W Meter lighting EL Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Engine trouble warning light LED EPS warning light LED Park indicator light LED On Command four wheel drive differential gear lock indicator LCD High range indicator light LED Low rang...

Page 169: ...Headlight fuse 15 0 A Signaling system fuse 5 0 A Ignition fuse 15 0 A Auxiliary DC jack fuse 15 0 A Four wheel drive motor fuse 15 0 A Radiator fan fuse 20 0 A U43P10E0 book Page 5 Thursday May 15 2008 2 55 PM ...

Page 170: ... erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key id...

Page 171: ... 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 Model label U43P10E0 book Page 2 Thursday May 15 2008 2 55 PM ...

Page 172: ...pose of noise control prior to its sale or delivery to the ul timate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system M...

Page 173: ... the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 U43...

Page 174: ...bsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also wa...

Page 175: ...d upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CUSTOMER SERVICE If your ma...

Page 176: ...e to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodg...

Page 177: ...costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 Indicates a potential hazard that could result in serious injury or death WARNING U43...

Page 178: ...11 9 11 EBU26132 U43P10E0 book Page 9 Thursday May 15 2008 2 55 PM ...

Page 179: ... 4 2 D Differential gear lock indicator light 4 4 Differential gear oil 5 4 8 29 Drive select lever 4 16 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 45 E Engine break in 6 4 Engine oil 5 4 Engine oil and oil filter cartridge 8 22 Engine stop switch 4 7 Engine trouble warning light 4 3 EPS warning light 4 3 F Final gear oil 5 4 8 27 Four wheel dr...

Page 180: ...ts lubricating 8 54 Reverse indicator light 4 2 Riding your ATV 7 1 S Safety information 1 1 Seat 4 19 Shock absorber assemblies adjusting the front and rear 4 22 Spark arrester cleaning 8 41 Spark plug checking 8 20 Specifications 10 1 Speed limiter 4 14 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 19 T...

Page 181: ...Wheel installing 8 64 Wheel removing 8 64 U43P10E0 book Page 3 Thursday May 15 2008 2 55 PM ...

Page 182: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 183: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 184: ... surfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELME...

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