Yamaha Grizzly YFM35FGIX Owner'S Manual Download Page 108

Page: 108 / 164

8-18

NOTE:

If the recommended oil is not available, SAE80W-
90 API GL-5 Hypoid gear oil may be used instead.
However, when using this oil, noise from the final
gear case may occur when applying the rear
brake.

CAUTION:

ECB00420

Be sure no foreign material enters the final
gear case.

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

specified torque.

8. Check the final gear case for oil leakage. If oil

is leaking, check for the cause.

9. Install the engine guard and the final gear

case guard by installing the bolts, and then
tightening them to the specified torques.

1. Final gear oil filler bolt
2. Correct oil level

3. Final gear oil

Recommended final gear oil:

See page 10-1.

Tightening torque:

Final gear oil filler bolt:

24 Nm (2.4 m·kgf, 17 ft·lbf)

Tightening torques:

Engine guard bolt:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Final gear case guard bolt:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

U4S211E0.book Page 18 Friday, May 25, 2007 9:38 AM

Summary of Contents for Grizzly YFM35FGIX

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL ...

Page 2: ...EBU17091 U4S211E0 book Page 1 Friday May 25 2007 9 38 AM ...

Page 3: ...n 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 TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL IN...

Page 4: ...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 5: ...nd spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17401 AFFIX DEALER LABEL HERE YFM35FGIX OWNER S MANUAL 2007 by Yamaha Motor Corporation U S A 1st edition April 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is exp...

Page 6: ...4 1 Main switch 4 1 Speed limiter 4 10 Front brake lever 4 11 Brake pedal and rear brake lever 4 12 Parking brake 4 13 Drive select lever 4 13 Recoil starter 4 14 Fuel tank cap 4 15 Fuel 4 15 Fuel cock 4 16 Starter choke 4 18 Seat 4 18 Storage compartment 4 19 Front carrier 4 20 Rear carrier 4 20 Adjusting the front and rear shock absorber assemblies 4 21 PRE OPERATION CHECKS 5 1 Pre operation che...

Page 7: ...23 WHAT TO DO IF 7 32 WHAT TO DO 7 32 PERIODIC MAINTENANCE AND MINOR 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 5 Removing and installing the panel 8 9 Checking the spark plug 8 10 Engine oil and oil filter cartridge 8 12 Final gear oil 8 16 Differential gear oil 8 19 Cleaning the air filter ...

Page 8: ...l 8 40 Checking the wheel hub bearings 8 40 Lubricating the drive shaft universal joint 8 40 Checking the stabilizer bushes 8 41 Lubricating the rear knuckle pivots 8 41 Lubricating the steering shaft 8 41 Battery 8 42 Replacing a fuse 8 44 Troubleshooting 8 50 Troubleshooting chart 8 51 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification ...

Page 9: ...struc tor Contact an authorized ATV dealer or call 1 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 Never operate a...

Page 10: ...o steep for the Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle 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 a...

Page 11: ... operate an ATV in 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 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 12: ...s open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the ATV in another vehi cle be sure it is kept upright and that the fuel cock is in the OFF position Other wise fuel may leak out of the carburetor or fuel tank HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some gas oline ...

Page 13: ...ust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad equate ventilation U4S211E0 book Page 5 Friday May 25 2007 9 38 AM ...

Page 14: ...2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U4S211E0 book Page 1 Friday May 25 2007 9 38 AM ...

Page 15: ...o read or comes off request a replace ment label from your Yamaha dealer Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an accident Never exceed the maximum front cargo limit of 40kg 88 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4877 00 WARNING 1 2 U4S211E0 book Page 2 Friday May 25 2007 9 3...

Page 16: ...2 U4S211E0 book Page 3 Friday May 25 2007 9 38 AM ...

Page 17: ...2 U4S211E0 book Page 4 Friday May 25 2007 9 38 AM ...

Page 18: ...ing ring 2 Fuel cock 3 Throttle stop screw 4 Fuses 5 Battery 6 Rear shock absorber assembly spring preload adjusting ring 1 Spark arrester 2 Storage compartment and tool kit 3 Air filter case 4 Spark plug 5 Rear brake light switch 6 Brake pedal 7 V belt case drain plug U4S211E0 book Page 1 Friday May 25 2007 9 38 AM ...

Page 19: ...om the figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Starter choke 4 Parking brake lock plate 5 Drive select lever 6 Speedometer 7 Main switch 8 Fuel tank cap 9 On Command four wheel drive differential gear lock switch U4S211E0 book Page 2 Friday May 25 2007 9 38 AM ...

Page 20: ...h The positions of the main switch are as follows ON All electrical systems are supplied with power The headlights meter lighting 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 U4S211E0 book Page 1 Friday May 25 2007 9 38 AM ...

Page 21: ...Oil temperature warning light This warning light comes on when the engine over heats When this occurs stop the engine as soon as it is safe to do so and allow it to cool The electrical circuit of the warning light can be checked by turning the key to ON with the engine stop switch set to and then pushing the start switch If the warning light does not come on while the start switch is being pushed ...

Page 22: ...Com mand four wheel drive switch is set to the 4WD position NOTE Due to the synchronizing mechanism in the differ EBU28341 On Command differential gear lock indicator light This indicator light and the On Command four wheel drive indicator light come on when the On Command differential gear lock switch is set to the LOCK position EBU18020 Speedometer The speedometer shows the riding speed This spe...

Page 23: ...g the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch 1 Reset knob 2 Speedometer 3 Odometer 4 Tripmeter 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE U4S211E0 book Page 4 Friday May 25 2007 9 38 AM ...

Page 24: ...ned off for an extended period of time 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 EBU28350 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 different...

Page 25: ...ition 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 have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO ...

Page 26: ...l wheels turn at the same speed 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 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 or from four wheel drive to two wheel drive while moving may cause the A...

Page 27: ...the differential gear lock switch in to the LOCK position When the dif ferential gear is locked the differential gear lock in dicator light comes on To release the differential gear lock stop the ATV and push the switch to the 4WD position 1 Differential gear lock lever 2 On Command four wheel drive switch 2WD 4WD 1 On Command differential gear lock switch 4WD LOCK U4S211E0 book Page 8 Friday May ...

Page 28: ...r wheel drive to differential gear lock or vice versa while moving may 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 WHAT CAN HAPPEN All wheels turn at the same...

Page 29: ...rting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released WARNING EWB00200 EBU18311 Speed limiter 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 C...

Page 30: ...ed on the right handle bar To apply the front brake pull the brake lever toward the handlebar grip 1 Locknut 2 Adjusting screw 3 No more than 12 mm 0 47 in 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...

Page 31: ...on the right side of the ATV and the rear brake lever is located on the left handlebar To apply the rear brake push down on the brake pedal or pull the brake lever toward the handlebar grip 1 Front brake lever 1 Brake pedal U4S211E0 book Page 12 Friday May 25 2007 9 38 AM ...

Page 32: ...ction on page 6 3 for the drive select lever operation 1 Parking brake lock plate POTENTIAL HAZARD WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start ing the engine This could cause loss of con trol or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could caus...

Page 33: ...l not to pull the rope all the way out WARNING EWB00300 1 Drive select lever 1 Recoil starter POTENTIAL HAZARD Starting the engine without shifting into the neutral position WHAT CAN HAPPEN The ATV could start to move unexpectedly which could cause an accident HOW TO AVOID THE HAZARD U4S211E0 book Page 14 Friday May 25 2007 9 38 AM ...

Page 34: ...cient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap 1 Fuel level 2 Fuel tank filler tube Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 13 5 L 3 57 US gal 2 97 Imp gal Fuel reserve amount 3 3 L 0 87 US gal 0 73 Imp gal U4S211E0 book Page 15 Friday May 25 2007 9 38 AM ...

Page 35: ...con tent 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 EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations WHAT CAN HAPPEN Fuel can spill which can cause a...

Page 36: ... this position when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark pointing to OFF 1 Arrow mark pointing to ON U4S211E0 book Page 17 Friday May 25 2007 9 38 AM ...

Page 37: ...as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Move the starter choke in direction b to turn off the starter choke See the Starting a cold engine section on page 6 1 for proper operation EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear 1 Arrow mark pointing to RES 1 Starter choke U4S211E0 book Page 18 Friday Ma...

Page 38: ...t is securely fitted EBU18911 Storage compartment CAUTION ECB00130 Do not store metal or sharply edged objects like tools in the storage compartment If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartment 1 Seat 2 Seat lock lever 1 Projection 2 Seat holder U4S211E0 book Page 19 Friday May 25 2007 9 38 AM ...

Page 39: ...If any water collects in this hose re move the hose empty it and then install it EBU18960 Front carrier Do not exceed the load limit of 40 0 kg 88 lb for the front carrier Do not exceed the maximum load of 210 0 kg 463 lb for the ATV EBU18970 Rear carrier Do not exceed the load limit of 80 0 kg 176 lb 1 Storage compartment 1 Storage compartment check hose U4S211E0 book Page 20 Friday May 25 2007 9...

Page 40: ...ws 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 WARNING EWB00350 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 U4S211E0 book Page 21 Friday May 25 2007 9 38 AM ...

Page 41: ...or death WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorber assem blies on the left and right side to the same setting U4S211E0 book Page 22 Friday May 25 2007 9 38 AM ...

Page 42: ...ine which service should be performed by a Yamaha dealer 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 inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedu...

Page 43: ...1 Rear brake Check operation and correct if necessary Lubricate cables if necessary Check lever and pedal free play and adjust if necessary 5 3 8 29 8 32 Throttle lever Make sure that operation is smooth Lubricate cable and lever hous ing if necessary Check cable free play and adjust if necessary 5 4 8 28 Control cables Make sure that operation is smooth Lubricate if necessary 8 38 Wheels and tire...

Page 44: ...play in the rear brake lever and brake pedal If the free play is incorrect ad just it See page 8 32 Check operation of the levers and pedal They should move smoothly and there should be a 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...

Page 45: ... If the brakes do not provide proper braking performance check the brake pads and friction plates for wear See page 8 29 EWB00540 EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary Recommended brake fluid DOT 4 WHAT CAN HAPPEN You could lose braking ability which could ...

Page 46: ...w have been approved by Yamaha Motor Manufacturing Corpora tion of America for this model Other tire combinations are not recommended Front Manufacturer model MAXXIS M979 Size AT25 x 8 12 Rear Manufacturer model MAXXIS M980 Size AT25 x 10 12 Type Tubeless The tires should be set to the recommend ed pressure Recommended tire pressure Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 k...

Page 47: ...specifications Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm Rear 250 kPa 36 psi 2 5 kgf cm Higher pre...

Page 48: ...d switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm 1 Tire wear limit U4S211E0 book Page 7 Friday May ...

Page 49: ... 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 collision HOW TO ...

Page 50: ...into the neutral position before starting the engine 5 Use the starter choke in reference to the fig ure Position 1 Cold engine start with ambient temperature below 5 C 40 F Position 2 Cold engine start with ambient temperature between 0 C 30 F and 30 C 90 F Ambient temp starter choke position 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE If the engine...

Page 51: ...osition 3 before riding NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter choke is not required when the engine is warm Instead start the engine with the throttle slightly open EBU20370 Operating the drive select lever and dri...

Page 52: ...g the shift NOTE When in reverse the reverse indicator light should come on If the indicator light does not come on have a Yamaha dealer check the electrical circuit 4 Check behind for people or obstacles and then release the brake pedal 1 Drive select lever 2 F Forward 3 N Neutral 4 R Reverse 1 Drive select lever 2 F Forward 3 N Neutral 4 R Reverse U4S211E0 book Page 4 Friday May 25 2007 9 38 AM ...

Page 53: ...e overheating must be avoided 0 160 km 0 100 mi or 0 10 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 ...

Page 54: ... slowly re lease the brake pedal 1 Parking brake lock plate WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the ATV transversely across the incline shift the drive select lever to the forward position stop the engine apply the parking brake and then block the...

Page 55: ...tion 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 limits your view Use ex...

Page 56: ...ng Ride more slowly than you would without a load The more weight you carry the slower you should go 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 MAXIMUM LOADING LIMIT ATV loading limit total weight ...

Page 57: ...nges in ATV handling which could lead to an accident 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 U4S211E0 book Page 9 Friday May 25 2007 9 38 AM ...

Page 58: ...7 EBU21131 RIDING YOUR ATV U4S211E0 book Page 1 Friday May 25 2007 9 38 AM ...

Page 59: ...quires special skills acquired through practice over a period of time Take the time to learn the ba sic 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 t...

Page 60: ... for 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 c...

Page 61: ... 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 U4S211E0 book Page 4 Friday May 25 2007 9 38 AM ...

Page 62: ... 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 U4S211E0 book Page 5 Friday May 25 2007 9 38 AM ...

Page 63: ...g without eye 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 sleeve...

Page 64: ...or drugs WHAT CAN HAPPEN Could seriously affect your judgment 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 inspect your ATV each time you use it to mak...

Page 65: ...ss 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 5 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 6 POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of...

Page 66: ...top speed See page 4 10 Loading 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 MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 210 0 kg 463 lb Front carrier 40 0 kg 88 lb Rear carrier 80 ...

Page 67: ...ident 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 U4S211E0 book Page 10 Friday May 25 2007 9 38 AM ...

Page 68: ...uce your ability to control the ATV or 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 wh...

Page 69: ...ich in some situations could 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 U4S211E0 book Page 12 Friday May 2...

Page 70: ...tem WHAT CAN HAPPEN Dry grass or brush or other combustible ma terial 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 exha...

Page 71: ...veways 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 U4S211E0 book Page 14 Friday May 25 2007 9 38 AM ...

Page 72: ...r terrain WHAT CAN HAPPEN You can come upon hidden 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 rou...

Page 73: ...ip 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 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 U4S211E0 book Page 16 Friday May 25 2007 9 38 AM ...

Page 74: ...the starter choke to the closed position shift the drive select lever into the forward position and then release the parking brake Apply the throttle 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 tho...

Page 75: ...bsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a colli sion or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Prac tice turning at low speeds before attempting to turn at faster speeds Do not t...

Page 76: ...at ground before attempting any in cline and then practice riding first on gentle slopes Try more difficult climbs only after you have devel oped your skill In all cases avoid inclines with slip pery or loose surfaces or obstacles that might WARNING EWB01090 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forw...

Page 77: ...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 could be on the other side of the hill U4S211E0 book Page 20 Friday May 25 2007 9 38 AM ...

Page 78: ...y 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 any hill Avoid crossing the side of a steep hill if pos sible When crossing the side o...

Page 79: ...HAZARD Stalling rolling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose all forward speed If you begin rolling backwards Keep weight uphill 2WD Never apply the rear brake while roll ing backwards Apply the front brake When fully stopped apply the rear brake as...

Page 80: ...When descending hills using either brake lever or the brake pedal 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 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...

Page 81: ...7 U4S211E0 book Page 24 Friday May 25 2007 9 38 AM ...

Page 82: ...your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING EWB01141 POTENTIAL HAZARD Improperly crossing hills or turning on hills HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique ...

Page 83: ...7 U4S211E0 book Page 26 Friday May 25 2007 9 38 AM ...

Page 84: ...1150 Test your brakes after leaving the water Do not continue to ride 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 w...

Page 85: ... air filter case the V belt cooling duct check hose the drive select lever box check hose and the storage compartment check hose Also remove the V belt case drain plug to drain any water that may have accumu lated Wash the ATV in fresh water if it has been 1 Air filter case check hose U4S211E0 book Page 28 Friday May 25 2007 9 38 AM ...

Page 86: ...e damage to the ATV or could lead to an upset 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 EWB01160 1 Drive select lever box check hose 1 V belt case drain plug U4S211E0 book Page 29 Friday May 25 2007 9 38 AM ...

Page 87: ...OW 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 Owner s Manual U4S211E0 book Page 30 Friday May 25 2007 9 38 AM ...

Page 88: ... wheels of your ATV start to slide side ways control can usually be regained if there is room to do so by steering in the direction of the With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are re duced Bear in mind that sliding maneuvers should always be avoided ...

Page 89: ...n the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 19 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards ...

Page 90: ... ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See page 7 27 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death U4S211E0 book Page 33 Friday May 25 2007 9 38 AM ...

Page 91: ...r DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01820 EBU21720 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and always carry it on the bottom of the seat as shown Put the owner s tool kit and low pres sure tire gauge under the seat POTENTIAL HAZARD Servicing an engine whi...

Page 92: ...erating 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 to this ATV should be genuine Yamaha or equivalent compo nen...

Page 93: ... should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 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 ...

Page 94: ...ss and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U4S211E0 book Page 4 Friday May 25 2007 9 38 AM ...

Page 95: ...ecessary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake lever and pedal free play and adjust if necessary Replace brake friction plates Whenever worn to the limit 4 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years 5 Wheels ...

Page 96: ... 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 correct if neces sary NO ...

Page 97: ...ct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 25 Front and rear brake switches Check operation and correct if necessary 26 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 1300 800 2500 1600 2500...

Page 98: ...s replace the internal components of the brake master cylinder and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U4S211E0 book Page 8 Friday May 25 2007 9 38 AM ...

Page 99: ...rm some of the maintenance jobs described in this chapter Refer to this section each time the panel needs to be removed and installed EBU23111 Panel A To remove the panel Remove the bolt and then take the panel off To install the panel Place the panel in the original position and install the bolt ECB00380 1 Panel A 1 Panel A 2 Bolt U4S211E0 book Page 9 Friday May 25 2007 9 38 AM ...

Page 100: ...t In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridd...

Page 101: ...o 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 DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in 1 Spark plug gap Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf U4S211E0 book P...

Page 102: ...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 NOTE If the engine was started before checking the oil 3 Remove the engine oil filler cap and then wipe the dipstick off with a clean rag 4 Insert th...

Page 103: ... the engine oil with or without oil fil ter cartridge replacement 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase 1 Dipstick 2 Maximum level mark 3 Minimum level mark ...

Page 104: ...lable at a nearby Yamaha dealer 6 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 7 Install the new oil filter cartridge with an oil fil 1 Oil filter cartridge 1 O ring U4S211E0 book Page 14 Friday May 25 2007 9 38 AM ...

Page 105: ...th 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 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt Recommended oil See page 10 1 Oil quantity Without oil filter cartridge replacement 2 20 L...

Page 106: ...the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oil level must be checked on a cold engine NOTE 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 suffi...

Page 107: ... final gear oil filler bolt and the fi nal gear oil drain bolt to drain the oil from the 5 Install the drain bolt and then tighten it to the specified torque 6 Add the recommended final gear oil to the brim of the filler hole as shown 1 Engine guard 2 Final gear case guard 3 Bolt 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 24 Nm 2 4 m kgf 17 ft lbf U4S211E0 book Page 17...

Page 108: ...for oil leakage If oil is leaking check for the cause 9 Install the engine guard and the final gear case guard by installing the bolts and then tightening them to the specified torques 1 Final gear oil filler bolt 2 Correct oil level 3 Final gear oil Recommended final gear oil See page 10 1 Tightening torque Final gear oil filler bolt 24 Nm 2 4 m kgf 17 ft lbf Tightening torques Engine guard bolt ...

Page 109: ...ace the ATV on a level surface NOTE The differential gear oil level must be checked on a cold engine 2 Remove the differential gear oil filler bolt and then check the oil level in the differential gear case NOTE 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 Insta...

Page 110: ...m the differential gear case 4 Install the drain bolt and then tighten it to the specified torque 5 Add the recommended differential gear oil to the brim of the filler hole as shown CAUTION ECB00410 Be sure no foreign material enters the differen 1 Differential gear oil drain bolt 1 Differential gear oil 2 Differential gear oil filler bolt 3 Correct oil level Recommended differential gear oil See ...

Page 111: ...ore frequently if you are riding in unusually wet or dusty areas NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air fil ter case 1 Remove the seat See page 4 18 2 Remove the air filter case cover by unhooking the holders Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ...

Page 112: ...the air filter case 4 Pull off the lock plate and then remove the sponge material from the air filter element frame 1 Air filter case cover holder 2 Air filter case cover 1 Air filter element U4S211E0 book Page 22 Friday May 25 2007 9 38 AM ...

Page 113: ...onge material when squeez ing it 7 Check the sponge material and replace it if 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material U4S211E0 book Page 23 Friday May 25 2007 9 38 AM ...

Page 114: ... the air filter case for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear an...

Page 115: ... EWB01910 1 Tailpipe 2 Spark arrester Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf POTENTIAL HAZARD Improper cleaning of the spark arrester 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 cleaning the spark arrester Always let the exhaust system c...

Page 116: ...he carburetor The carburetor should be checked and if neces sary adjusted at the intervals specified in the peri odic maintenance and lubrication chart The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment 1 V bel...

Page 117: ...ecified in the periodic maintenance and lubrica tion chart NOTE A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it up NOTE The engine is warm when it quickly responds to the throttle crease the engine idling speed turn the throt tle stop screw in direction a and to decrease it turn the screw in direction b NOTE If the specified idling speed cannot be obtained ...

Page 118: ...nd ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle cable free play turn the adjusting bolt in direction b 3 Tighten the locknut EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise T...

Page 119: ...e rear brake friction plates must be checked for wear at the intervals specified in the periodic maintenance and lubrica tion chart NOTE This ATV is equipped with a wet multiple disc type rear brake which is located inside of the final gear case EBU24171 Front brake pads Check each front brake pad for damage and mea sure the lining thickness If a brake pad is dam aged or if the lining thickness is...

Page 120: ...r limit mark have a Yamaha dealer replace the brake friction plates as a set EBU24251 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly causing it to become inef fective Before riding 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 l...

Page 121: ...l 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 EBU24280 tion have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EBU24380 C...

Page 122: ...he brake lever and brake pedal free play check the rear brake friction plates for wear Adjusting the brake pedal and brake lever free play The brake pedal free play should measure 17 0 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 ope...

Page 123: ... the brake lever free play adjusting bolt 2 Fully loosen the brake lever free play adjust ing nut on the brake cable at the final gear case 1 Brake pedal free play 1 Locknut 2 Brake lever free play adjusting bolt U4S211E0 book Page 33 Friday May 25 2007 9 38 AM ...

Page 124: ...2 5 3 0 mm 0 10 0 12 in 4 Push the brake camshaft lever in direction a until it stops apply approximately 50 N 5 1 kgf 11 2 lbf of force and then turn the brake lever free play adjusting nut on the brake ca ble at the final gear case so that gap B mea sures 4 0 6 0 mm 0 16 0 24 in 1 Brake lever free play adjusting nut 1 Brake pedal free play adjusting nut 2 Brake camshaft lever 3 Gap A U4S211E0 bo...

Page 125: ...n b to decrease it 6 Tighten the locknut at the brake lever NOTE When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move Checking the brake pedal position The top of the brake pedal should be positioned 1 Brake lever free play adjusting nut 2 Brake camshaft lever 3 Gap B 1 Locknut 2 Brake lever free play adjusting bolt U4S211E0 b...

Page 126: ...ose 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 Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer U4S211E0 book Page 36 Friday May 25 2007 9 38 AM ...

Page 127: ...tervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them re placed by a Yamaha dealer 1 Front axle boot each side 1 Rear axle boot each side U4S211E0 book Page 37 Friday May 25 2007 9 38 AM ...

Page 128: ... braking takes effect 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direc tion a To make the brake light come on lat er turn the adjusting nut in direction b 3 Install the panel EBU24890 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each r...

Page 129: ...maged 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 cables frequently Replace damaged cables Recommended lubricants Front brake lever Silicone grease Rear brake lever Lithium soap based grease all ...

Page 130: ... pivot remove panel A See page 8 9 EBU24962 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU24970 Lubricating the drive shaft universal U4S211E0 book Page 40 Frid...

Page 131: ...s The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the pivoting points using a grease gun 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 Recommended lubricant Li...

Page 132: ...ories 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 of children Antidote EXTERNAL Flush ...

Page 133: ...he battery leads to the battery terminals CAUTION ECB00630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a 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...

Page 134: ...8 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits ECB00640 1 Main fuse 2 Spare main fuse 3 Fuse box 1 Headlight fuse 2 Ignition fuse 3 Four wheel drive motor fuse 4 Signaling system fuse 5 Spare fuse U4S211E0 book Page 44 Friday May 25 2007 9 38 AM ...

Page 135: ...adlight 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 30 0 A Headlight fuse 15 0 A Ignition fuse 15 0 A Four wheel drive motor fuse 10 0 A Signaling system fuse 10 0 A POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could le...

Page 136: ... the bulb hold er by pushing it in 1 Headlight bulb holder cover 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 U4S211E0 book Page 46 Friday May 25 2007 9 38 AM ...

Page 137: ...hol or thinner CAUTION ECB00670 Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 8 Adjust the headlight beam if necessary EBU25550 Adjusting a headlight beam CAUTION ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the adjusting screw in direction a To lower a headlight beam turn the adjusting ...

Page 138: ...l 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 EBU25700 Installing a wheel 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward 1 Headlight beam adjusting screw 1 Wheel nut U4S211E0 book Page 48 Friday May 25 2007 9 38 AM ...

Page 139: ...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 U4S211E0 book Page 49 Friday May 25 2007 9 38 AM ...

Page 140: ... 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 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame ...

Page 141: ...Have a Yamaha dealer 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 The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The battery is good Dry Wet O...

Page 142: ...0710 Excessive water pressure may cause water 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 clean wa ter and dry all surfaces w...

Page 143: ...loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing 5 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 WHAT CAN ...

Page 144: ...les and the pivoting points of all levers and pedals 7 Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery ...

Page 145: ...and fuel 275 0 kg 606 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Compression ratio 9 20 1 Starting system Electric and recoil starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 YAMALUBE 4 CW 5W30 or SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE...

Page 146: ...ommended fuel Unleaded gasoline only Fuel tank capacity 13 5 L 3 57 US gal 2 97 Imp gal Fuel reserve amount 3 3 L 0 87 US gal 0 73 Imp gal Carburetor Manufacturer Spark plug s Manufacturer model NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Shaft drive Secondary reduction ratio...

Page 147: ...ld tires Recommended Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm 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 Type We...

Page 148: ...city 12 V 12 0 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage x quantity Headlight Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Oil temperature warning light 12 V 1 7 W 1 On command four wheel drive indicator light 12 V 1 7 W 1 Differential gear lock indicator light 12 V 1 7 W x 1 Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignit...

Page 149: ... ref 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 1 Key identifi...

Page 150: ...050 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 1 Vehicle identification number front left side 1 Model label U4S211E0 book Page 2 Friday May 25 2007 9 38 AM ...

Page 151: ...ose 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 Mu...

Page 152: ...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 U4S2...

Page 153: ...sequent 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 war...

Page 154: ...y set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha ATV dealer within the c...

Page 155: ...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 lodgin...

Page 156: ...y expires You can also save money Y E S 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 U4S211E0 book Page 8 Friday May 25 2007 9 38 ...

Page 157: ...11 EBU26132 U4S211E0 book Page 9 Friday May 25 2007 9 38 AM ...

Page 158: ...ont and rear 5 3 C Cables checking and lubricating 8 38 Carburetor adjusting 8 26 Carrier front 4 20 Carrier rear 4 20 Drive select lever 4 13 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 29 Drive shaft universal joint lubricating 8 40 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 27 Engine oil 5 3 Engine oil and oil filter ca...

Page 159: ...9 Parking 6 6 Parking brake 4 13 Parking on a slope 6 6 Part locations 3 1 S Safety information 1 1 Seat 4 18 Shock absorber assemblies adjusting the front and rear 4 21 Spark arrester cleaning 8 24 Spark plug checking 8 10 Specifications 10 1 Speed limiter 4 10 Speedometer 4 3 Stabilizer bushes checking 8 41 Starter choke 4 18 Start switch 4 5 Steering shaft lubricating 8 41 Storage 9 2 Storage c...

Page 160: ...Warranty limited 11 5 Wheel hub bearings checking 8 40 Wheel installing 8 48 Wheel removing 8 48 U4S211E0 book Page 3 Friday May 25 2007 9 38 AM ...

Page 161: ...U4S211E0 book Page 4 Friday May 25 2007 9 38 AM ...

Page 162: ...ct 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 HELMET AND PROTECTIVE GEAR NEVER USE ON PU...

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Yamaha Grizzly YFM35FGIX, Owner'S Manual

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