Yamaha GRIZZLY YFM700FWAD Owner'S Manual Download Page 121 | Manualshive

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9-18

9

EBU38131

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 ac-
cordance with the periodic maintenance and lubri-
cation chart. In addition, the condition of the spark
plug can reveal the condition of the engine.

To remove the spark plug

1. Remove panels A, C and E. (See page 9-10.)
2. Remove the spark plug cap.

3. Remove the spark plug as shown, with the

spark plug wrench included in the tool kit.

Tightening torques:

Panel bolt:

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

Footboard nut:

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

1. Spark plug cap

1. Spark plug wrench

1

1

UBDE60E0.book Page 18 Monday, April 22, 2019 4:12 PM

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Summary of Contents for GRIZZLY YFM700FWAD

Page 1: ...AIRE MANUAL DEL PROPIETARIO BDE F8199 60 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad ...

Page 2: ...DIC183 Original instructions Notice originale Manual original PRINTED IN USA 2019 05 0 5 1 CR E F S ...

Page 3: ...LY It contains important safety information WARNING OWNER S MANUAL YFM70GPAL YFM70GPSL YFM700FWAD This ATV should not be ridden by anyone under 16 years of age BDE F8199 60 E0 UBDE60E0 book Page 1 Monday April 22 2019 4 12 PM ...

Page 4: ...he Netherlands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title and or number and date of issue of standard...

Page 5: ...nformation It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manual completely before operating your ATV Make sure you understand all instructions For mode...

Page 6: ...the figures shown in this manual This is the 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 vehic...

Page 7: ...torway Please check your local riding laws and regulations before operating this ATV EBU17411 YFM70GPAL YFM70GPSL YFM700FWAD OWNER S MANUAL 2020 by Yamaha Motor Co Ltd 1st edition March 2019 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A UBDE60E0 book Page 1 Monday April 22 2019 4 12 PM ...

Page 8: ...ver 5 16 Speed limiter 5 16 Front brake lever 5 17 Brake pedal and rear brake lever 5 17 Drive select lever 5 18 Fuel tank cap 5 19 Fuel 5 20 Seat 5 21 Storage compartments 5 22 Front carrier 5 26 Rear carrier 5 26 Front and rear shock absorbers 5 26 Winch equipped models 5 28 Trailer hitch 5 28 Auxiliary DC jack 5 29 PRE OPERATION CHECKS 6 1 Fuel 6 3 Engine oil 6 3 Final gear oil 6 3 Differential...

Page 9: ... system 9 3 Periodic maintenance chart General maintenance and lubrication 9 5 Removing and installing panels 9 10 Checking the spark plug 9 18 Engine oil and oil filter cartridge 9 20 Why Yamalube 9 24 Final gear oil 9 25 Differential gear oil 9 27 Coolant 9 29 Cleaning the air filter element 9 37 Cleaning the spark arrester 9 40 V belt case drain plug 9 41 Adjusting the throttle lever free play ...

Page 10: ... Replacing a fuse 9 56 Replacing a headlight bulb 9 58 Adjusting a headlight beam 9 60 Brake tail light 9 61 Removing a wheel 9 61 Installing a wheel 9 62 Troubleshooting 9 63 Troubleshooting charts 9 64 CLEANING AND STORAGE 10 1 Cleaning 10 1 Storage 10 2 SPECIFICATIONS 11 1 CONSUMER INFORMATION 12 1 Emissions Certification label for Europe 12 1 INDEX 13 1 UBDE60E0 book Page 3 Monday April 22 201...

Page 11: ...E IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26032 Vehicle identification number The vehicle identification number is stamped into the frame This 17 digit number is used to identify your individual ATV EBU26053 Model label The model label is affixed at the location shown 1 Vehicle identification number front left side UBDE60E0 book Page 1 Monday April 22 2019 4 12 PM ...

Page 12: ... specific model can be identified by checking the model type code found on the model label 1 Model label 1 Model type code 2 Production code 3 Color code 1 1 3 2 UBDE60E0 book Page 2 Monday April 22 2019 4 12 PM ...

Page 13: ... all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a re placement label from your Yamaha dealer UBDE60E0 book Page 1 Monday April 22 2019 4 12 PM ...

Page 14: ...2 2 2 For Europe 2 1 3 4 5 7 6 6 8 9 6 6 13 12 10 11 UBDE60E0 book Page 2 Monday April 22 2019 4 12 PM ...

Page 15: ...500 SHINGAI IWATA JAPAN YFM700FWAD 36 0 kW 330 kg 2019 B4F F155A 60 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWAD 36 0 kW 354 kg 2019 B4F F155A 70 B16 F817R 10 90 kg 198 lbs B16 F817R 00 50 kg 110 lbs 1P0 F816P 20 YAMAHA 1 BDE2 1 BDE7 BDEA BDEE 1 BDEJ 2 3 4 UBDE60E0 book Page 3 Monday April 22 2019 4 12 PM ...

Page 16: ...cm 5 0 psi 30 0 kPa 0 30 kgf cm 4 4 psi 50 0 kPa 0 50 kgf cm 7 3 psi 50 0 kPa 0 50 kgf cm 7 3 psi YAMAHA B5K F816M M0 35 0 kPa 0 35 kgf cm 5 0 psi 35 0 kPa 0 35 kgf cm 5 0 psi 50 0 kPa 0 50 kgf cm 7 3 psi 50 0 kPa 0 50 kgf cm 7 3 psi 5 7 BDE2 BDE7 BDEA BDEE 7 BDEJ 6 UBDE60E0 book Page 4 Monday April 22 2019 4 12 PM ...

Page 17: ...2 5 2 YAMAHA 1HP F811R 00 E10 E5 B4F F817K 00 10 8 9 UBDE60E0 book Page 5 Monday April 22 2019 4 12 PM ...

Page 18: ...2 6 2 37S F816N 00 0 5 kg 1 lb B4F F817R 10 4 kg 9 lbs 1P0 F816R 00 YAMAHA 12 13 11 UBDE60E0 book Page 6 Monday April 22 2019 4 12 PM ...

Page 19: ...ective gear Use from 16 years old Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER use on paved roads NEVER carry passengers NEVER use with drugs or alcohol NEVER store fuel or flammable liquids This unit contains high pressure nitrogen gas Mishandling can cause an explosion Do not incinerate puncture or open UBDE60E0 book Page 7 Monday April ...

Page 20: ...can cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all other load related items Make sure you do not exceed the load limits Overloadi...

Page 21: ...2 9 2 For Oceania 1 2 3 4 6 11 10 7 8 9 5 5 UBDE60E0 book Page 9 Monday April 22 2019 4 12 PM ...

Page 22: ...0 YAMAHA MAXIMUM LOADING LIMIT 37S F151K 00 PULLING LOAD 5880 N 600 kgf 1322 lbf TONGUE WEIGHT 147 N 15 kgf 33 lbf YAMAHA WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 1 2 3 4 UBDE60E0 book Page 10 Monday April 22 2019 4 12 PM ...

Page 23: ...th cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Maximum Vehicle Load 240 kg 530 lbs Includes weight of operator cargo and accessories and if applicable trailer tongue weight WARNING B16 F816M 00 YAMAHA IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set w...

Page 24: ...islodge from the rim Cargo or a trailer can affect stability and handling Read owner s manual before loading or towing When riding with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Maximum Vehicle Load 240 kg 530 lbs Includes weight of operator cargo and accessories and if applicable trailer tongue weight WARNING B4F F816M 00 YAMAHA IMPROPER TIRE...

Page 25: ...tion at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S...

Page 26: ...ild under 16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV This vehicle is intended for off road use only Do not operate on any paved surfaces such...

Page 27: ...ting to turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shif...

Page 28: ...h as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never 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 leaving water If necessary apply them several times to let friction dry out the linings Always be sure there ar...

Page 29: ...ssary If you can physically operate your vehicle inspect your vehicle If the vehicle is in safe operating con dition and you can safely operate it restart it and ride gently back to camp or other known location where you can receive medical at tention If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If yo...

Page 30: ...hange any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries re lated to changes in the vehicle Keep the following guidelines in mind as well as those found in the Loading section page 7 6 when mounting acces sories Never install accessories that would impair the performance of your ATV Carefully i...

Page 31: ...nd you can quickly be overcome and unable to save yourself Also deadly levels of carbon monoxide can linger for hours or days in en closed or poorly ventilated areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors...

Page 32: ...il dipstick 7 Oil filter cartridge 8 Coolant reservoir 5 1 2 3 4 6 7 8 1 Rear storage compartment 2 Fuel tank cap 3 Tool kit 4 Center storage compartment 5 Spark plug 6 Winch equipped models 7 Front shock absorber 8 Brake pedal 9 V belt case drain plug 10 Rear shock absorber 5 6 1 7 10 2 3 4 8 9 UBDE60E0 book Page 1 Monday April 22 2019 4 12 PM ...

Page 33: ...r brake fluid reservoir 6 Winch switch equipped models 7 Multi function display 8 Front brake fluid reservoir 9 On Command 4WD switches 10 Throttle lever 11 Front brake lever 12 Front storage compartment 13 Main switch 14 Auxiliary DC jack 1 6 2 34 7 8 9 11 10 12 14 13 5 UBDE60E0 book Page 2 Monday April 22 2019 4 12 PM ...

Page 34: ... EBU29913 Main switch on All electrical systems are supplied with power The engine can be started The key cannot be re moved off All electrical systems are off The key can be re moved 1 Main switch 1 UBDE60E0 book Page 1 Monday April 22 2019 4 12 PM ...

Page 35: ... EBU38080 Park indicator light This indicator light comes on when the transmis sion is in the park position EBU27982 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on 1 Differential gear lock indicator light 2 Low range indicator light L 3 High range indicator light H 4 Neutral indicator light N 5 Reverse indicator light R 6 Park indicator l...

Page 36: ...mains on have a Yamaha deal er check the vehicle NOTICE ECB02040 The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the warning light is out Continuous use while this warn ing light is on may cause damage to the en gine EBU30483 Engine trouble warning light This warning light comes on or flashes if a problem is dete...

Page 37: ...s too heavy i e excessive steering use when the ATV is traveling at a slow speed the power assist is reduced to protect the EPS motor from overheating EBU38100 Four wheel drive icon differential gear lock icon and indicator light The four wheel drive icon comes on when the drivetrain is set to 4WD four wheel drive The differential gear lock icon and the differ ential gear lock indicator light come...

Page 38: ...peedometer can be set to MPH or km h This also changes the odometer and trip meter units between miles and kilometers To change the display between MPH and km h turn the key to off then while holding the SELECT button pushed turn the key to on 1 Speedometer 2 Odometer Tripmeter A Tripmeter B Service tripmeter Error code display 3 Clock Hour meter Voltage display Coolant temperature display 4 Fuel ...

Page 39: ...s reset at the last maintenance Push the SELECT button to switch between the odometer ODO the tripmeters TRIP A and TRIP B and the service tripmeter in the following order ODO TRIP A TRIP B ODO To reset a tripmeter set the display to the tripme ter you want to reset then push the RESET but ton for 2 seconds TIP The odometer will lock at 199999 The tripmeters will reset and continue counting after ...

Page 40: ...e coolant temperature display in the following order CLOCK HOUR VOLT CLOCK To set the clock 1 Set the display to the clock 2 Push both the SELECT button and RE SET button for 2 seconds The hour digits will start flashing 3 Push the RESET button to set the hours 4 Push the SELECT button and the minute digits will start flashing 5 Push the RESET button to set the minutes 6 Push the SELECT button and...

Page 41: ...pair the vehicle Coolant temperature display When the coolant is in the normal operating tem perature range the temperature is displayed When the coolant temperature rises the coolant temperature display will begin to flash If the cool ant temperature continues to rise the message Hi will flash TIP The coolant temperature display can be set to C or F To switch the temperature units turn the key to...

Page 42: ...ly 4 0 L 1 06 US gal 0 88 Imp gal of fuel remains Refuel as soon as possible TIP If the electrical circuit for the fuel gauge is not working correctly all display segments will flash repeatedly Have a Yamaha dealer check the vehi cle Brightness control mode This mode allows you to adjust the brightness of the multi function display when the vehicle is stopped To adjust the brightness 1 Push the SE...

Page 43: ...cted in any of those circuits the engine trouble warning light will come on or flash and the display will indicate an error code If the display indicates an error code note the code number and have a Yamaha dealer check the vehicle NOTICE ECB00812 If the multi function display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage 1 Error code dis...

Page 44: ...op the engine in an emergency situa tion The engine will not start or run when this switch is set to 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE 5 Horn switch 6 Winch switch OUT IN equipped models 4 3 2 6 1 5 1 On Command drive switch 2WD 4WD 2 On Command drive switch 4WD LOCK 3 Drive switch lock lever 2WD 4WD LOCK 4WD 3 3 2 1 UBDE60E0 book Page 11 Monday Apri...

Page 45: ...he engine If this should happen remove the bat tery and recharge it See page 9 52 EBU18171 Horn switch Press the switch to sound the horn EBUM0432 Winch switch OUT IN equipped models This switch is used when operating the winch page 5 28 Read this manual and the Basic Guide to Winching Techniques completely before operating the winch switch EBU18192 Override switch OVERRIDE Top speed is normally l...

Page 46: ...ugh turn for the speed you are trav eling EBU2660A On Command drive switch 2WD 4WD Stop the ATV and push this switch to change from two wheel drive to four wheel drive or vice versa Select the appropriate drive according to the ter rain and riding conditions 2WD two wheel drive power is supplied to the rear wheels only giving a smooth ride and fuel economy 4WD four wheel drive power is supplied to...

Page 47: ...ear is locked Unlike in four wheel drive all wheels turn at the same speed giving maximum traction WARNING EWB00132 Always stop the ATV before changing from four wheel drive to four wheel drive differen tial gear lock or vice versa The ATV handles differently in four wheel drive than in differential gear lock in some circum stances Changing from four wheel drive to differential gear lock or vice v...

Page 48: ...en the ATV is in four wheel drive differential gear lock the maximum traveling speed is limit ed to 35 km h 22 mi h However if conditions require full engine power to be available push and hold the override switch to disable the dif ferential gear lock speed limiter See page 5 12 WARNING EWB00141 Always ride at a slow speed when the ATV is in differential gear lock and allow extra time and distanc...

Page 49: ...throttle from fully opening even when the throttle lever is pushed to the maximum Adjusting the speed limiter 1 Loosen the locknut 2 To increase the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in direction a To decrease the maximum engine power avail able and the maximum speed of the ATV turn 1 Throttle lever 2WD 4WD 1 1 Locknut 2 Adjusting screw 3 No m...

Page 50: ...ent of the speed limiter and throttle could cause throttle cable damage or improper throttle operation You could lose control resulting in an accident EWB00242 3 Tighten the locknut EBU18393 Front brake lever The front brake lever is located on the right han dlebar To apply the front brake pull the brake le ver toward the handlebar grip EBU18444 Brake pedal and rear brake lever 1 Front brake lever...

Page 51: ... the brake pedal or pull the brake lever toward the handlebar grip EBU18614 Drive select lever The drive select lever is used to shift the transmis sion into the low range high range neutral re verse and park positions See page 7 2 for drive select lever operation 1 Rear brake lever 1 1 Drive select lever 1 UBDE60E0 book Page 18 Monday April 22 2019 4 12 PM ...

Page 52: ...el while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the su...

Page 53: ...eath Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes For Europe TIP Confirm the gasoline pump nozzle has the same fuel identification mark Recomme...

Page 54: ...0 E10 Gas oline containing methanol is not recommended because it can cause damage to the fuel system or vehicle performance problems NOTICE ECB00071 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system EBU34141 Seat To remove the seat Pull up the seat at the rear and then pull t...

Page 55: ...B00831 Do not store metal or sharply edged objects like tools in the storage compartments If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartments The front storage compartment is located at the front right side of the ATV To access the storage compartment remove the storage compartment cover by turning it counterclockwise 1 Projection 2 Seat h...

Page 56: ... located in front of the seat To access the storage compart ment open the storage compartment lid 1 Front storage compartment 1 Center storage compartment lid 1 Center storage compartment 1 1 UBDE60E0 book Page 23 Monday April 22 2019 4 12 PM ...

Page 57: ...hat they will not get wet When washing the ATV be careful not to let any water enter the stor age compartments Do not exceed the load limit of 0 5 kg 1 lb for the front storage compartment 4 0 kg 9 lb for the center storage compartment or 2 0 kg 4 lb for the rear storage compartment Do not exceed the maximum load of 240 0 kg 530 lb for the ATV 1 Rear storage compartment lid 2 Rear storage compartm...

Page 58: ...y water collects in a storage compartment remove the drain plug drain the water and then install the drain plug 1 Front storage compartment drain plug 1 Center storage compartment drain plug 1 Rear storage compartment drain plug 1 1 UBDE60E0 book Page 25 Monday April 22 2019 4 12 PM ...

Page 59: ...sorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac cident 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 suspensi...

Page 60: ... 1 Special wrench Front spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 Rear spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 UBDE60E0 book Page 27 Monday April 22 2019 4 12 PM ...

Page 61: ...p hands away from fairlead when winding the winch rope NOTICE ECBM0051 Prolonged winching can overheat the winch motor and can drain the vehicle s battery even when the engine is idling Allow the winch mo tor to cool and the battery to recharge between uses EBU28972 Trailer hitch This ATV is equipped with a 5 cm 2 in trailer hitch receiver Trailer towing equipment can be obtained at a Yamaha deale...

Page 62: ... DC jack 1 Trailer hitch receiver 1 1 Auxiliary DC jack cap 2 Auxiliary DC jack Auxiliary DC jack system capacity 10 0 A 120 W BDE3 BDEK 6 0 A 72 W BDE2 BDE7 BDEA BDEE BDEJ 2 1 UBDE60E0 book Page 29 Monday April 22 2019 4 12 PM ...

Page 63: ...engine is running and the headlights are turned off 1 Start the engine 2 Turn the headlights off 3 Turn the accessory off 4 Open the auxiliary DC jack cap 5 Insert the accessory power plug into the jack 6 Turn the accessory on TIP When inserting or removing the accessory pow er plug turn the accessory off When the auxiliary DC jack is not being used cover it with the cap NOTICE ECB00122 If accesso...

Page 64: ...y a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 5 20 6 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 6 3 9 20 Final gear oil Check ATV for o...

Page 65: ...Throttle lever Make sure that operation is smooth Lubricate cable and lever housing if necessary Check lever free play and adjust if necessary 6 4 9 42 Control cables Make sure that operation is smooth Lubricate if necessary 9 49 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 6 4 Brake ...

Page 66: ...dd coolant as necessary See page 9 29 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU29083 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front and rear brake levers If there is free play have a Yamaha dealer check the brake system Check for correct free play in the brake pedal If the free play ...

Page 67: ... check the brake pads for wear See page 9 43 EBU19762 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 EBU38062 Tires Check and adjust the tire pressure before each ride Check tires for wear and damage Tire pressure A low pressure tire gauge is included as standard equipment M...

Page 68: ...from loss of control or rollover Tire pressure below the minimum specified could also cause the tire to dislodge from the rim under severe driving conditions EWB04120 OPERATING TIRE PRESSURE cold For Oceania Front Recommended 35 0 kPa 0 350 kgf cm 5 0 psi Rear Recommended 30 0 kPa 0 300 kgf cm 4 4 psi BDE3 35 0 kPa 0 350 kgf cm 5 0 psi BDEK Front Minimum 32 0 kPa 0 320 kgf cm 4 6 psi Rear Minimum ...

Page 69: ...DEJ Front Minimum 32 0 kPa 0 320 kgf cm 4 6 psi Rear Minimum 27 0 kPa 0 270 kgf cm 4 0 psi BDE2 BDE7 BDEA BDEE 32 0 kPa 0 320 kgf cm 4 6 psi BDEJ With cargo or trailer Front Recommended 50 0 kPa 0 500 kgf cm 7 3 psi Rear Recommended 50 0 kPa 0 500 kgf cm 7 3 psi Front Minimum 45 0 kPa 0 450 kgf cm 6 5 psi Rear Minimum 45 0 kPa 0 450 kgf cm 6 5 psi Maximum load Vehicle 240 0 kg 530 lb The vehicle s...

Page 70: ... risk of an acci dent Front Manufacturer model MAXXIS MU01Y BDEJ BDEK MAXXIS MU05Y BDE2 BDE7 BDEA BDEE BDE3 Size AT26 x 8 12 BDE2 BDE7 BDEA BDEE BDE3 AT27 x 10 14 BDEJ BDEK Rear Manufacturer model MAXXIS MU01Y BDEJ BDEK MAXXIS MU06Y BDE2 BDE7 BDEA BDEE BDE3 Size AT26 x 10 12 BDE2 BDE7 BDEA BDEE BDE3 AT27 x 10 14 BDEJ BDEK Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2...

Page 71: ...of handling braking and comfort Other tires rims sizes and combinations may not be appropriate EBU19841 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened EBU19851 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary UBDE60E0 book Page 8 Monday April 22 2019 4 12 PM ...

Page 72: ...d to shift into neutral or park and apply the rear brake when starting the engine NOTICE ECB00151 See the Engine break in section on page 7 4 prior to operating the engine for the first time To start the engine 1 Turn the key to on and the engine stop switch to run The battery voltage warning light the cool ant temperature warning light and the en gine trouble warning light should come on for a fe...

Page 73: ...re than 10 seconds on any single attempt NOTICE ECB00164 For maximum engine life never accelerate hard when the engine is cold EBU36230 Operating the drive select lever and driving in reverse NOTICE ECB03330 Do not shift without coming to a complete stop and waiting for the engine to return to normal idle speed Damage to the engine or drivetrain may occur Shifting Neutral to High range and High ra...

Page 74: ...ople or ob stacles behind you When it is safe to proceed go slowly 1 Bring the ATV to a complete stop 2 Apply the brake pedal 3 Shift from neutral to reverse or from reverse to park and vice versa by moving the drive se lect lever along the shift guide 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park 1 2 3 4 5 6 L H N R P 1 Drive select lever 2 L Low range 3 H Hig...

Page 75: ...or the first 240 km 150 mi or 20 hours During this period the various parts in the engine wear and polish themselves to the cor rect operating clearances Avoid prolonged full throttle operation or any condition that might re sult in engine overheating 0 120 km 0 75 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not oper ate it at one set thrott...

Page 76: ... applying the brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to the park position EBU20911 Accessories and loading EBU20922 Genuine Yamaha Accessories Choosing accessories for your ATV is an impor tant decision Genuine Yamaha Accessories which are available only from a Yamaha dealer have been designed tested and approved by Yamaha for use on your ATV Many comp...

Page 77: ... 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 extra caution when...

Page 78: ...ad can cause an accident Make sure the load does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier ATV takes...

Page 79: ...d 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 UBDE60E0 book Page 8 Monday April 22 2019 4 12 PM ...

Page 80: ...8 1 8 EBU21142 RIDING YOUR ATV UBDE60E0 book Page 1 Monday April 22 2019 4 12 PM ...

Page 81: ...n on pages 3 1 3 6 Also read all warn ing and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01382 Do not operate this ATV or allow anyone else to operate it without proper instruction 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 ...

Page 82: ...at are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WARNING Never carry a passenger Carrying a passenger on this ATV greatly reduces your ability to balance and contro...

Page 83: ...G Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01412 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating wi...

Page 84: ...each time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 6 1 Always follow the inspection and mainte nance procedures and schedules described in the Owner s Manual WARNING Failure to inspect the ATV before riding it or failure to maintain it properly increases the possibility of an acci dent and equipment damage EWB01433 Speed limiter...

Page 85: ... centered side to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier vehicle ...

Page 86: ...ould cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident EWB01472 MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rid er accessories and tongue 240 0 kg 530 lb Front carrier 50 0 kg 110 lb Rear carrier 90 0 kg 198 lb Front storage compartme...

Page 87: ... installa tion or use of accessories or other modification All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be in stalled and used according to instructions If you have questions consult an authorized ATV dealer WARNING Operating this ATV with improper modifications may cause changes in handling which in some situ...

Page 88: ... it The muffler and other engine parts become ex tremely hot during operation and remain hot after the engine has stopped To reduce the risk of fire during operation or after leaving the ATV do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to other hot parts Check under the vehicle after operating in areas where combustible mate rials ma...

Page 89: ...other vehicles Make sure you know your country s laws and regulations before you ride on unpaved public streets or roads Do not ride on any paved public street road or motor way WARNING Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle EWB01522 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or root...

Page 90: ...g on excessively rough slippery or loose terrain could cause loss of traction or ATV con trol which could result in an accident includ ing an overturn EWB01542 When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where ...

Page 91: ...gin riding your ATV With the engine idling shift the drive select lever into the low range position or the high range position 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 until you are thorough...

Page 92: ... the ATV will resist turning A special turning tech nique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed As you approach a curve slow down and begin to turn the handlebars in the desired direction As you do so put your weight on the footboard to the outside of the turn opposite your desired direc tion and lean your upper...

Page 93: ... UPHILL WARNING EWB01672 Climbing hills improperly can cause overturns or loss of control Use proper riding techniques described in this Owner s Manual Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Always check the terrain carefully before you start up any hill Never climb h...

Page 94: ... momentum but not so fast that you cannot react to changes in the terrain as you climb 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 forward and on steeper inclines standing on the footboards and leaning forward over the handlebars When ever possible ride straight up hills Slow down when you reach the crest ...

Page 95: ...are inter connected by the drive train applying either brake will brake all wheels therefore avoid sudden ap plication of either the front or rear brake as the wheels on the uphill side could come off the ground The ATV could easily tip over backwards Apply both the front and rear brakes gradually When fully stopped lock shift to the park position and dismount the ATV immediately on the uphill sid...

Page 96: ...or maximum engine com pression braking effect select the low range posi tion and change to 4WD before beginning to descend the hill Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the ...

Page 97: ...requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loos...

Page 98: ...e risk of an overturn The ATV can be used to cross slow moving shal low water of up to a maximum of 35 cm 14 in in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and carefully Test your brakes after leaving the water If neces sary apply them several times to let...

Page 99: ... of the air filter case Also remove the drain plugs from the storage compartments and the V belt case to drain any water that may have accu mulated NOTICE Undrained water can cause damage or improper operation ECB00842 Wash the ATV in fresh water if it has been operat ed in salt water or muddy conditions 1 Air filter case check hose 1 Front storage compartment drain plug 1 UBDE60E0 book Page 20 Mo...

Page 100: ... as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to an upset or 1 Center storage compartment drain plug 1 Rear storage compartment drain plug 1 1 1 V belt case drain plug 1 UBDE60E0 book Page 21 M...

Page 101: ... slowly and be very cautious in order to re duce the chance of skidding or sliding out of control Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help...

Page 102: ... Position your weight over the front wheels for better control See page 8 13 If your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See page 8 13 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recomm...

Page 103: ... you discover that the ATV is going to tip over dismount on the uphill side See page 8 18 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa 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 S...

Page 104: ...Turn off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 3 6 for more information about carbon monoxide WARNING EWB02691...

Page 105: ...luded in this manual and the tools provided in the tool kit are intended to assist you in the performance of preventive maintenance and minor repairs However additional tools such as a torque wrench are necessary to perform cer tain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s Manual 2 Tool...

Page 106: ... ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 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 Crankcase breath er system Chec...

Page 107: ...reed valve and hose for damage Replace any damaged parts if necessary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 UBDE60E0 book Page 4 Monday April 22 2019 4 12 PM ...

Page 108: ...uld 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 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check operation and correct...

Page 109: ...and replace if nec essary 7 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 8 Wheel hub bearings Check for looseness or damage and replace if necessary 9 V belt Check for wear cracks or other damage and re place if necessary 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened NO ITEM CHECK OR M...

Page 110: ...d Check toe in and adjust if necessary 16 Engine mount Check for cracks or other damage and replace if necessary 17 Axle boots Check for cracks or other damage and replace if necessary 18 Engine oil Change Check ATV for oil leakage and correct if neces sary 19 Engine oil filter car tridge Replace 20 Differential gear oil Change Check ATV for oil leakage and correct if neces sary NO ITEM CHECK OR M...

Page 111: ...2 years 23 Moving parts and cables Lubricate 24 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 25 Front and rear brake switches Check operation and 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 ...

Page 112: ...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 UBDE60E0 book Page 9 Monday April 22 2019 4 12 PM ...

Page 113: ...nance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU34720 Panel A To remove the panel Pull upward on the areas shown 1 Panel A 2 Panel B 3 Panel C 4 Panel D 5 Panel F 2 1 3 4 5 1 Panel E 2 Panel G 2 1 UBDE60E0 book Page 10 Monday April 22 2019 4 12 PM ...

Page 114: ... the panel in the original position Panel B To remove the panel 1 Remove panel A 2 Remove the front carrier by removing the bolts 1 Panel A 1 1 Front carrier 2 Carrier bolt upper 1 2 2 UBDE60E0 book Page 11 Monday April 22 2019 4 12 PM ...

Page 115: ...ll 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 Carrier bolt under the fenders 2 Carrier bolt lower 1 2 2 1 1 Panel B 2 Quick fastener 3 Projection 3 3 1 2 3 2 UBDE60E0 book Page 12 Monday April 22 2019 4 12 PM ...

Page 116: ...move the seat See page 5 21 2 Remove panel A 3 Remove the hoses from panel C 4 Remove the quick fasteners and bolts Tightening torques Carrier bolt upper 34 N m 3 4 kgf m 25 lb ft Carrier bolt lower 34 N m 3 4 kgf m 25 lb ft Carrier bolt under the fenders 7 N m 0 7 kgf m 5 2 lb ft 1 Panel C 2 Hose 2 1 2 UBDE60E0 book Page 13 Monday April 22 2019 4 12 PM ...

Page 117: ...ull the panel upward to remove it TIP To ease removal of panel C shift the drive select lever into the reverse position To install the panel 1 Place the panel in the original position 1 Bolt 2 Quick fastener 1 2 1 Screw 1 1 UBDE60E0 book Page 14 Monday April 22 2019 4 12 PM ...

Page 118: ...operly connected and routed and are not pinched 3 Install panel A 4 Install the seat Panels D and E To remove a panel 1 Remove panels A and C 2 Remove the bolt and then pull the panel up ward to remove it 1 Panel D 2 Bolt 1 Panel E 2 Bolt 1 2 1 2 UBDE60E0 book Page 15 Monday April 22 2019 4 12 PM ...

Page 119: ...tion and then install the bolt 2 Install panels A and C Panels F and G To remove a panel 1 Remove the panel bolts footboard bolt and footboard nut 1 Panel F 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection UBDE60E0 book Page 16 Monday April 22 2019 4 12 PM ...

Page 120: ...ion To install a panel 1 Place the panel in the original position 2 Install the bolts and nut and then tighten them to the specified torques 1 Panel G 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection UBDE60E0 book Page 17 Monday April 22 2019 4 12 PM ...

Page 121: ...lubri cation chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove panels A C and E See page 9 10 2 Remove the spark plug cap 3 Remove the spark plug as shown with the spark plug wrench included in the tool kit Tightening torques Panel bolt 4 0 N m 0 40 kgf m 3 0 lb ft Footboard nut 4 0 N m 0 40 kgf m 3 0 lb ft 1 Spark plug cap 1...

Page 122: ...the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification To install the spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark...

Page 123: ...he oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrica tion chart To check the engine oil level 1 Park the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level warm up the engine and then wait at least 10 minutes until the oil settles for an accurate reading 3 Remove the access ...

Page 124: ...the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level NOTICE Be sure the engine oil is at the correct level otherwise engine damage may result ECB00852 7 Insert the dipstick completely into the oil filler hole 8 Install the access cover by turning it clock wise 1 Engine oil dipstick 1 Maximum level mark 2 Minimum level mark UBDE60E0 book Page 21 Monday...

Page 125: ...and then remove the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 6 10 if the oil filter cartridge is not be ing replaced 6 Remove panel F See page 9 10 7 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer 8 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge 1...

Page 126: ...torque with a torque wrench 10 Install panel F 11 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the spec ified torque 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 N m 1 7 kgf m 13 lb ft Tightening torque Engine oil drain bolt 33 N m 3 3 kgf m 24 lb ft UBDE60E0 book Page 23 Monday April 22 2019 4 12 PM ...

Page 127: ...ine off wait at least ten minutes and then check the oil level and correct it if necessary 15 Install the access cover by turning it clock wise EBU38620 Why Yamalube YAMALUBE oil is a Genuine YAMAHA Part born of the engineers passion and belief that engine oil is an important liquid engine component We form teams of specialists in the fields of mechanical en gineering chemistry electronics and tra...

Page 128: ...als speci fied in the periodic maintenance and lubrication chart To check the final gear oil level 1 Park the ATV on a level surface 2 Remove the final gear oil level check bolt and its gasket and then check the oil level in the final gear case 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 its gas ke...

Page 129: ... 3 Remove the final gear oil filler bolt the final gear oil level check bolt the final gear oil drain bolt and their gasket to drain the oil from the final gear case 4 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 1 Final gear oil filler bolt 2 Gasket Tightening torques Final gear oil level check bolt 10 N m 1 0 kgf m 7 4 lb ft Final gear oil filler bo...

Page 130: ...gear oil The differential gear case must be checked for oil leakage before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In addition the differential gear oil level must be checked and the oil changed as follows at the in tervals specified in the periodic maintenance and lubrication chart Tightening torque Final gear oil drain bolt 23 N m 2 3 kgf m 17 lb ft 1 Fina...

Page 131: ...the oil filler bolt and its gasket and then tighten the bolt to the specified torque To change the differential gear oil 1 Park 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 the differential gear oil drain bolt and their gasket to drain the oil from the differential gear case 1 Differential gear...

Page 132: ...d torque 8 Check the differential gear case for oil leak age If oil is leaking check for the cause EBU23472 Coolant The coolant level should be checked regularly In addition the coolant must be changed at the in tervals specified in the periodic maintenance and lubrication chart Tightening torque Differential gear oil drain bolt 9 8 N m 0 98 kgf m 7 2 lb ft 1 Differential gear oil filler bolt 2 Ga...

Page 133: ...to the en gine EBU34201 To check the coolant level 1 Park the ATV on a level surface TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser voir TIP The coolant should be between the minimum and maximum level marks Recommended coolant YAMALUBE coolant Coolant quantity Coolant reservoir up to full level ...

Page 134: ... of coolant replace it with coolant as soon as possible otherwise the cooling system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze con tent of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECB01012 TIP The radiator fan is automatically switched on or off according to th...

Page 135: ...er pressure Always place a thick rag over the cap when opening Allow any remaining pressure to escape before completely removing the cap 1 Park the ATV on a level surface 2 Remove panels A B C and D See page 9 10 3 Remove the footboard by removing the bolts and nuts 4 Remove the radiator cap 1 Footboard 2 Bolt and nut 3 Bolt 3 2 2 3 1 UBDE60E0 book Page 32 Monday April 22 2019 4 12 PM ...

Page 136: ... remove the coolant drain bolt and its gasket Use a trough or a similar object as shown to prevent coolant from spilling on the engine guard 1 Radiator cap 1 1 Coolant drain bolt 2 Gasket 1 Trough 1 2 1 UBDE60E0 book Page 33 Monday April 22 2019 4 12 PM ...

Page 137: ...w gas ket and then tighten the bolt to the specified torque 11 Connect the coolant reservoir hose 12 Pour the recommended coolant into the radi ator until it is full 13 Pour the recommended coolant into the res ervoir to the maximum level mark and then install the reservoir cap 14 Loosen the water pump air bleed bolt with out removing it to allow all of the air to es cape from the air bleed bolt h...

Page 138: ... to es cape from the air bleed bolt hole 19 When coolant begins to flow out of the bolt hole tighten the cylinder head air bleed bolt to the specified torque 20 Start the engine and let it idle for ten minutes 21 Rev the engine five times Tightening torque Water pump air bleed bolt 10 N m 1 0 kgf m 7 4 lb ft 1 V belt cooling duct 2 Clamp screw 1 2 1 Cylinder head air bleed bolt Tightening torque C...

Page 139: ...ap 24 Start the engine and then check for coolant leakage TIP If any leakage is found have a Yamaha dealer check the cooling system 25 Install the V belt cooling duct and then tight en the clamp screw 26 Install the footboard by installing the bolts and nuts and then tighten them to the speci fied torques TIP Tighten footboard bolts B in the order shown 1 Footboard nut 2 Footboard bolt A 3 Footboa...

Page 140: ...lly wet or dusty areas TIP 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 Park the ATV on a level surface Tightening torques Footboard nut 4 0 N m 0 40 kgf m 3 0 lb ft Footboard bolt A 4 0 N m 0 40 kgf m 3 0 lb ft Footboard bolt B 8 N m 0 8 kgf m 5 9 lb ft 4 1 2 3 1 Air filter ...

Page 141: ...holders 4 Pull the air filter element out of the air filter case 5 Pull off the air filter element 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 2 1 1 Air filter element 1 UBDE60E0 book Page 38 Monday April 22 2019 4 12 PM ...

Page 142: ...pply Yamaha foam air filter oil or other qual ity foam air filter oil to the sponge material TIP The sponge material should be wet but not drip ping 10 Pull the sponge material over the air filter ele ment frame and then install the lock plate 11 Insert the air filter element into the air filter case and then install the air filter case cover by hooking the holders onto the air filter case NOTICE ...

Page 143: ... and the rubber joint man ifold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine EBU28905 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester WARNING EWB02342 Always let the exhaust system cool prior to touching exhaust components Do not start the engine with the spa...

Page 144: ...e bolt holes 6 Install the bolts and tighten to the specified torque EBU23932 V belt case drain plug After riding in water deep enough to allow it to en ter the V belt case remove the V belt case drain plug to drain the water from the case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the water may affect other engine parts Tightening torque...

Page 145: ... resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance and lu brication chart EBU29602 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be performed by a Yamaha dealer WARNING EWB02572 Operating with improper...

Page 146: ...tor groove which allows you to check the brake pad wear without having to disassemble the brake If a brake pad has worn to the point that the wear in dicator groove has almost disappeared have a Yamaha dealer replace the brake pads as a set TIP The wheels need to be removed to check the brake pads See page 9 61 Front brake Rear brake 1 Wear indicator groove 1 Wear indicator groove UBDE60E0 book Pa...

Page 147: ...NOTICE ECB01161 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid im mediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indicate worn brake pads or brake sys tem leakage Therefore be sure to check the 1 Minimum level mark 2WD 4WD 1 1 Minimum level mark Specified brake fluid DOT 4 UBDE60E0 boo...

Page 148: ...kage Refill with the same type of brake fluid Add ing a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the flu id and may result in vapor lock EBU24293 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specifie...

Page 149: ...ree play Front brake Rear brake There should be no free play at the brake lever end If there is free play have a Yamaha dealer in spect the brake system 1 No brake lever free play 1 No brake lever free play 1 UBDE60E0 book Page 46 Monday April 22 2019 4 12 PM ...

Page 150: ... wear 1 Remove panel G See page 9 10 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 Brake pedal free play 1 0 6 0 mm 0 04 0 24 in 1 ...

Page 151: ...nd brake pedal do not move EBU24231 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them replaced by a Yamaha dealer 1 Brake pedal cable joint 2 Slight play 0 1 0 5 mm 0 004 0 02 in 1 2 1 Front axle boot each side 1 1 UBDE60E0 book Page 48 Monday Ap...

Page 152: ... operation of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an accident or collision EBU24913 Checking and lubricating the front and rear brake levers The operation of the front and rear brake leve...

Page 153: ...dal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel G See page 9 10 Recommended lubricant Lithium soap based grease UBDE60E0 book Page 50 Monday April 22 2019 4 12 PM ...

Page 154: ...U25023 Checking the stabilizer bushes 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 EBU25054 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication ch...

Page 155: ...e use a grease gun EBU2904F Battery This model is equipped with a 12 volt VRLA valve regulated lead acid battery There is no need to check the electrolyte or add distilled wa ter However the battery lead connections need to be checked and tightened and the battery ter minals cleaned if corroded If the battery seems to have discharged recharge it as soon as possible 1 Grease nipple Recommended lubr...

Page 156: ...ote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ignition away Ventilate when charging or using in an enclosed space KEEP OUT OF RE...

Page 157: ... lead ECB01002 5 Pull the battery out of its compartment NOTICE ECB00622 Never attempt to open the battery or remove the battery cell seals as this would permanent ly damage the battery To charge the battery Confirm the recommended charging rate as specified on the battery itself 1 Carrier bolt under the fenders 2 Carrier bolt lower 1 2 2 1 1 Battery holding plate 2 Nut 3 Negative battery lead bla...

Page 158: ...e battery in a discharged state for an extended period of time will cause permanent battery damage Do not store the battery in an excessively cold or warm place below freezing or above 30 C 90 F To install the battery 1 Place the battery in its compartment 2 Connect the positive battery lead first then connect the negative battery lead by installing their bolt NOTICE When installing the bat tery t...

Page 159: ... EBU30525 Replacing a fuse Tightening torques Carrier bolt upper 34 N m 3 4 kgf m 25 lb ft Carrier bolt lower 34 N m 3 4 kgf m 25 lb ft Carrier bolt under the fenders 7 N m 0 7 kgf m 5 2 lb ft 1 Fuse box 2 Main fuse 3 EPS fuse 4 Fuel injection system spare fuse 5 Fuel injection system fuse 2 3 4 5 1 UBDE60E0 book Page 56 Monday April 22 2019 4 12 PM ...

Page 160: ...wn fuse and then install a new fuse of the specified amperage WARNING Always use a fuse of the spec ified rating and never use a substitute ob ject in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical system which could lead to a fire EWB02173 1 Headlight fuse 2 Signaling system fuse 3 Radiator fan motor fuse 4 Ignition fuse 5 Four wheel drive moto...

Page 161: ...y the top half of each lamp will illuminate When the headlights are set to high beam both halves of each lamp will illuminate Handlebar mounted light If the handlebar mounted light bulb burns out re place it with the specified bulb as follows 1 Remove the handlebar mounted light cover by removing the quick fasteners Specified fuses Main fuse 40 0 A Headlight fuse 10 0 A Ignition fuse 10 0 A Four w...

Page 162: ...h the glass part of the bulb Oil from your fingers or other contamination will adversely affect the transparency of the glass luminosity of the bulb and bulb life Thoroughly clean off any dirt and fin gerprints using a cloth moistened with al cohol or thinner ECB00653 1 Handlebar mounted light cover 2 Quick fastener 1 Bulb cover 1 2 2 1 1 Socket 1 UBDE60E0 book Page 59 Monday April 22 2019 4 12 PM...

Page 163: ...the quick fasteners 9 Adjust the handlebar mounted light beam if necessary EBU25553 Adjusting a headlight beam NOTICE ECB00691 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b 1 Do not touch the glass part of the bulb 1 1 Handlebar mounted l...

Page 164: ...EBU25653 Removing a wheel 1 Park the ATV on a level surface 2 Loosen the wheel nuts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel 1 Handlebar mounted light beam adjusting screw 1 Adjusting screw left and right headlights b a 1 b a 1 1 Wheel nut 1 1 UBDE60E0 book Page 61 Monday April 22 2019 4 12 PM ...

Page 165: ... be sure to install the nuts with their tapered side towards the wheel 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques 1 Arrow mark 2 Forward rotating direction 3 Wheel nut 1 3 3 2 1 Tapered nut Tightening torques Front wheel nut 55 N m 5 5 kgf m 41 lb ft Rear wheel nut 55 N m 5 5 kgf m 41 lb ft 1 UBDE60E0 book Page 62 Monday April 22 2019 4 12 PM ...

Page 166: ...any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience 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 EWB02281 Do not smoke when checking the fuel system Fuel can ignite or...

Page 167: ...e the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Check the compression Dry Wet Operate the electric starter Have a Yamaha dealer check the ATV The engine does not start Check the ignition Operate the electric starter 2 Battery The engine turns over qui...

Page 168: ...mended coolant as soon as possible The engine will tend to overheat if the radiator is caked with mud or if the ATV is overloaded Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If ...

Page 169: ...tion dry out the linings EWB02312 NOTICE Excessive wa ter pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure de tergent applications such as those avail able in coin operated car washers ECB00712 4 Once most of the dirt has been hosed off wash all surfaces with w...

Page 170: ...the following steps to protect the en gine from internal 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 several times with the st...

Page 171: ...10 3 10 8 Remove the battery and fully charge it See page 9 52 UBDE60E0 book Page 3 Monday April 22 2019 4 12 PM ...

Page 172: ...epth 35 cm 14 in Weight Curb weight 313 0 kg 690 lb BDE3 325 0 kg 716 lb BDE2 330 0 kg 728 lb BDE7 BDEA BDEE 342 0 kg 754 lb BDEK 354 0 kg 780 lb BDEJ Loading Maximum loading limit 240 0 kg 530 lb Total weight of rider cargo accessories and tongue Noise and vibration level Noise level 77 311 EEC 78 0 dB A at 3125 r min BDE2 BDE7 BDEA BDEE 79 0 dB A at 3125 r min BDEJ Uncertainty of measurement 0 5...

Page 173: ...40 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Quantity Oil change 2 00 L 2 11 US qt 1 76 Imp qt With oil filter removal 2 10 L 2 22 US qt 1 85 Imp qt Final gear oil Type Yamaha Friction Modified Plus Shaft Drive Oil Part No ACC SHAFT PL 32 or SAE 80 API GL 4 Hypoid gear oil Quantity 0 20 L 0 21 US qt 0 18 Imp qt Differential gear oil Type Yamaha Friction Mod...

Page 174: ...0 Spark plug s Manufacturer model NGK CPR7EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Drivetrain Primary reduction ratio 1 000 Secondary reduction ratio 10 142 41 21 x 17 12 x 20 15 x 33 12 Final drive Shaft Clutch type Wet centrifugal shoe Transmission type CVT automatic with reverse Gear ratio Transmission ratio 2 380 0 700 1 Reverse gear 2 000 23 14 x 28 23 Low range 1 938 31 16 High range 1 ...

Page 175: ...EE 35 0 kPa 0 350 kgf cm 5 0 psi BDEJ Minimum Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi BDE2 BDE7 BDEA BDEE 32 0 kPa 0 320 kgf cm 4 6 psi BDEJ With cargo or trailer For Europe Recommended Front 50 0 kPa 0 500 kgf cm 7 3 psi Rear 50 0 kPa 0 500 kgf cm 7 3 psi Minimum Front 45 0 kPa 0 450 kgf cm 6 5 psi Rear 45 0 kPa 0 450 kgf cm 6 5 psi Front wheel Rim size 12 x 6 0 AT ...

Page 176: ...2 V 18 0 Ah Lights Headlight LED Handlebar mounted light T15H 35 0 W 36 5 W Brake tail light LED Meter lighting LED Neutral indicator light LED High beam indicator light LED Reverse indicator light LED Coolant temperature warning light LED Park indicator light LED Engine trouble warning light LED High range indicator light LED Low range indicator light LED Differential gear lock indicator light LE...

Page 177: ...tual level of exposure of work force include the characteristics of the work room the other sources of noise etc i e the number of machines and other adjacent process es and the length of time for which an operator is exposed to the noise Also the permissible expo sure level can vary from country This information however will enable the user of the machine to make a better evaluation of the hazard...

Page 178: ...combustion engines of non road mobile machinery Your Yamaha engine was designed and tested to give an optimal blend of performance without ex cessive emissions Therefore do not attempt to alter the engine specifications or tamper with the intake engine or exhaust systems NOTICE ECB03790 Tampering with the engine or emissions con trol system will void the European Union type approval of this engine...

Page 179: ...rning light 5 3 D Differential gear oil 6 3 9 27 Drive select lever 5 18 Drive select lever and driving in reverse 7 2 E Emissions Certification label for Europe 12 1 Engine break in 7 4 Engine oil 6 3 Engine oil and oil filter cartridge 9 20 Engine stop switch 5 11 Engine trouble warning light 5 3 EPS warning light 5 4 F Final gear oil 6 3 9 25 Four wheel drive differential gear lock icon 5 4 Fou...

Page 180: ... S Safety information 3 1 Seat 5 21 Shock absorber assemblies adjusting the front and rear 5 26 Spark arrester cleaning 9 40 Spark plug checking 9 18 Specifications 11 1 Speed limiter 5 16 Stabilizer bushes checking 9 51 Starting the engine 7 1 Start switch 5 12 Steering shaft lubricating 9 52 Storage 10 2 Storage compartments 5 22 T Throttle lever 5 16 6 4 Throttle lever free play adjusting 9 42 ...

Page 181: ...UBDE60E0 book Page 3 Monday April 22 2019 4 12 PM ...

Page 182: ... APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND...

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