Yamaha KODIAK 2019 Owner'S Manual Download

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9-22

TIP

Make sure that the O-ring is properly seated.

9. Install the new oil filter cartridge with an oil fil-

ter wrench, and then tighten it to the specified
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)

UB5K62E0.book Page 22 Thursday, May 9, 2019 2:59 PM

Summary of Contents for KODIAK 2019

Page 1: ...AIRE MANUAL DEL PROPIETARIO B5K F8199 62 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 6 1 CR E F S ...

Page 3: ...LLY It contains important safety information WARNING OWNER S MANUAL YFM700FWBD YFM700FWB YFM70KPAL This ATV should not be ridden by anyone under 16 years of age B5K F8199 62 E0 UB5K62E0 book Page 1 Thursday May 9 2019 2 59 PM ...

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

Page 5: ...standing of the features and operation of this ATV This manual includes important safety information It provides information about special techni ques 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 manu...

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 vehi...

Page 7: ...otorway Please check your local riding laws and regulations before operating this ATV EBU17411 YFM700FWBD YFM700FWB YFM70KPAL OWNER S MANUAL 2020 by Yamaha Motor Co Ltd 1st edition April 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 UB5K62E0 book Page 1 Thursday May 9 2019 2 59 PM ...

Page 8: ...D 4WD YFM700FWB 5 17 Throttle lever 5 18 Speed limiter 5 18 Front brake lever 5 19 Brake pedal and rear brake lever 5 19 Drive select lever 5 20 Fuel tank cap 5 21 Fuel 5 22 Seat 5 23 Storage compartment 5 24 Front carrier 5 25 Rear carrier 5 26 Front and rear shock absorbers YFM700FWBD YFM70KPAL 5 26 Trailer hitch 5 27 Auxiliary DC jack 5 28 PRE OPERATION CHECKS 6 1 Fuel 6 3 Engine oil 6 3 Final ...

Page 9: ...ol system 9 3 Periodic maintenance chart General maintenance and lubrication 9 5 Removing and installing panels 9 9 Checking the spark plug 9 17 Engine oil and oil filter cartridge 9 19 Why Yamalube 9 23 Final gear oil 9 24 Differential gear oil 9 26 Coolant 9 28 Cleaning the air filter element 9 36 Cleaning the spark arrester 9 39 V belt case drain plug 9 40 Adjusting the throttle lever free play...

Page 10: ...haft 9 52 Battery 9 53 Replacing a fuse 9 56 Replacing a headlight bulb 9 59 Adjusting a headlight beam 9 62 Replacing the brake tail light bulb 9 63 Removing a wheel 9 64 Installing a wheel 9 64 Troubleshooting 9 65 Troubleshooting charts 9 66 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...

Page 11: ...LE 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 UB5K62E0 book Page 1 Thursday May 9 2019 2 59 PM ...

Page 12: ...r 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 UB5K62E0 book Page 2 Thursday May 9 2019 2 59 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 UB5K62E0 book Page 1 Thursday May 9 2019 2 59 PM ...

Page 14: ...2 2 2 For Europe 1 2 3 4 5 11 9 10 7 8 6 UB5K62E0 book Page 2 Thursday May 9 2019 2 59 PM ...

Page 15: ...6 F817R 10 90 kg 198 lbs B16 F817R 00 50 kg 110 lbs 1P0 F816P 20 YAMAHA YAMAHA BB5 F816M M0 35 0 kPa 0 35 kgf 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 1 2 3 4 5 UB5K62E0 book Page 3 Thursday May 9 2019 2 59 PM ...

Page 16: ...AHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWBD 36 0 kW 323 kg 2019 B5K F155A 70 YAMAHA 1HP F811R 00 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWB 36 0 kW 313 kg 2019 B6K F155A 30 E10 E5 B4F F817K 00 6 B6KA 6 B5KJ 6 B5KN B5KS B5KV 7 8 9 UB5K62E0 book Page 4 Thursday May 9 2019 2 59 PM ...

Page 17: ...2 5 2 1P0 F816R 00 YAMAHA B4F F817R 10 4 kg 9 lbs 10 11 UB5K62E0 book Page 5 Thursday May 9 2019 2 59 PM ...

Page 18: ...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 UB5K62E0 book Page 6 Thursday May ...

Page 19: ... 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 Overload...

Page 20: ...2 8 2 For Oceania 3 5 4 9 6 7 8 1 2 UB5K62E0 book Page 8 Thursday May 9 2019 2 59 PM ...

Page 21: ...30 YAMAHA MAXIMUM LOADING LIMIT 37S F151K 00 PULLING LOAD 5880 N 600 kgf 1322 lbf TONGUE WEIGHT 147 N 15 kgf 33 lbf YAMAHA WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 1 2 3 4 UB5K62E0 book Page 9 Thursday May 9 2019 2 59 PM ...

Page 22: ...d 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 with tires cold LOADING TRAILER TOWING WARNING NEVER operate this ATV if you are under age 16 Operating this ATV if you ...

Page 23: ...tions 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 MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 4XE F15...

Page 24: ...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 25: ...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 26: ...ch 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 a...

Page 27: ...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 28: ...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 29: ...and 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 door...

Page 30: ...ester 6 Rear brake light switch 7 Engine oil dipstick 8 Oil filter cartridge 9 Coolant reservoir 5 1 2 3 4 7 8 6 9 1 Rear shock absorber 2 Fuel tank cap 3 Tool kit 4 Storage compartment 5 Spark plug 6 Front shock absorber 7 Brake pedal 8 V belt case drain plug 5 1 6 2 3 4 7 8 UB5K62E0 book Page 1 Thursday May 9 2019 2 59 PM ...

Page 31: ... fluid reservoir 8 Front brake lever 9 Throttle lever 10 Auxiliary DC jack 11 Main switch 1 2 3 4 5 6 7 8 9 1011 1 Drive select lever 2 Rear brake lever 3 Handlebar switches 4 Horn switch 5 Multi function display 6 Front brake fluid reservoir 7 On Command 4WD switches 8 Front brake lever 9 Throttle lever 10 Auxiliary DC jack 11 Main switch 1 2 3 5 6 7 8 9 1011 4 UB5K62E0 book Page 2 Thursday May 9...

Page 32: ...ical systems are off The key can be re moved EBU26699 Indicator lights and warning lights YFM700FWB 1 Main switch 1 1 Fuel level warning light 2 Engine trouble warning light 3 Coolant temperature warning light 4 Neutral indicator light N 5 Reverse indicator light R 6 Park indicator light P 7 Four wheel drive indicator light 1 2 3 4 5 6 7 UB5K62E0 book Page 1 Thursday May 9 2019 2 59 PM ...

Page 33: ...on when the transmis sion is in the reverse position EBU38270 Park indicator light YFM700FWB YFM700FWBD YFM70KPAL This indicator light comes on when the transmis sion is in the park position 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 light 7 Four wheel drive icon 8 Di...

Page 34: ...if the warning light remains on have a Yamaha dealer 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 YFM700FWB If the light comes on during operation stop the ve hicle as soon ...

Page 35: ... light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to on or if the warning light remains on have a Yamaha dealer check the vehicle YFM700FWB This warning light comes on or flashes when an electrical circuit monitoring the engine is not work ing correctly When this occurs have a Yamaha dealer check the self diagnosis system...

Page 36: ...ve indicators Four wheel drive indicator light YFM700FWB This indicator light comes on when the drivetrain is set to 4WD four wheel drive TIP Due to the synchronizing mechanism in the differ ential gear case the light may not come on until the ATV starts moving Four wheel drive icon YFM700FWBD YFM70KPAL This icon comes on when the drivetrain is set to 4WD four wheel drive TIP Due to the synchroniz...

Page 37: ...e display Speedometer The speedometer shows the vehicle s traveling speed The speedometer 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...

Page 38: ...as 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 39: ...he 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 an...

Page 40: ...epair 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 t...

Page 41: ...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 42: ...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 43: ...700FWBD YFM70KPAL 1 Light switch OFF 2 Engine stop switch 3 Start switch 4 Horn switch 3 4 2 1 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE 5 Horn switch 4 1 3 2 5 UB5K62E0 book Page 12 Thursday May 9 2019 2 59 PM ...

Page 44: ...ght headlights low beams and the taillight Set the switch to to turn on the left and right head lights high beams the handlebar mounted light YFM700FWBD YFM70KPAL and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00046 Do not use the headlights with the engine turned off for an extended period of time The battery may discharge to the point that the starter will not have ...

Page 45: ... of the speedometer appear as shown when the switch is NOT being pushed this could indicate a malfunction in the electrical system In this case take the ATV to a Yamaha dealer at the first opportunity WARNING EWB00151 Always ride at a slow speed when the ATV is in four wheel drive differential gear lock and al low extra time and distance for maneuvers All wheels turn at the same speed when the dif...

Page 46: ...trol and of causing an accident EBU30467 On Command drive switch 4WD LOCK YFM700FWBD YFM70KPAL Stop the ATV and push this switch to change from standard four wheel drive to four wheel drive with the differential locked Select the appropriate switch position according to the terrain and the conditions 4WD four wheel drive power is supplied to the front and rear wheels with the front differen tial u...

Page 47: ...ht are flashing will cause the vehicle speed to be limited until the differential gear is completely engaged or disengaged When the ATV is in four wheel drive differential gear lock the maximum traveling speed is limit ed to 35 km h 22 mi h However if conditions require full engine power to be available push and hold the override switch to disable the dif ferential gear lock speed limiter See page...

Page 48: ...heel drive Power is supplied to the front and rear wheels giving increased trac tion WARNING EWB00164 Always stop the ATV before changing from two wheel drive to four wheel drive and vice versa The ATV handles differently in two wheel drive than in four wheel drive in some circumstances Changing from two wheel drive to four wheel drive or vice versa while moving may cause the ATV to unexpectedly h...

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 UB5K62E0 book Page 20 Thursday May 9 2019 2 59 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: ...death 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 Recomm...

Page 54: ...10 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 ...

Page 55: ...E ECB02320 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 The storage compartment is located in front of the seat To access the storage compartment open the storage compartment lid 1 Projection 2 Seat holder 1 1 2 2 1 Storage compartment lid 1 UB5K62E0 bo...

Page 56: ...ed the maximum load of 240 0 kg 530 lb for the vehicle TIP A drain plug is fitted at the bottom of the storage compartment If any water collects in the storage compartment remove the drain plug drain the water and then install the drain plug EBU18964 Front carrier Do not exceed the load limit of 50 0 kg 110 lb for the front carrier Do not exceed the maximum load of 240 0 kg 530 lb for the ATV 1 St...

Page 57: ...neven 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 suspension Align the appropriate notch in the adjusting ring with the posi...

Page 58: ... 6 for precaution in formation 1 Special wrench Front spring preload setting Minimum soft 1 YFM700FWBD YFM70KPAL Standard 2 YFM700FWBD YFM70KPAL Maximum hard 5 YFM700FWBD YFM70KPAL Rear spring preload setting Minimum soft 1 YFM700FWBD YFM70KPAL Standard 2 YFM700FWBD YFM70KPAL Maximum hard 5 YFM700FWBD YFM70KPAL UB5K62E0 book Page 27 Thursday May 9 2019 2 59 PM ...

Page 59: ...ion of accessories that require more than the stated capacity at any one time This may overload the circuit and cause the fuse to blow 1 Trailer hitch receiver 1 1 Auxiliary DC jack cap 2 Auxiliary DC jack Auxiliary DC jack system capacity 10 0 A 120 W 2 1 UB5K62E0 book Page 28 Thursday May 9 2019 2 59 PM ...

Page 60: ...n 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 accessories are used with the engine off or with the headlights on the battery may dis charge to the point th...

Page 61: ...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 22 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 19 Final gear oil Check ATV for o...

Page 62: ...er free play and adjust if necessary 6 4 9 41 Control cables Make sure that operation is smooth Lubricate if necessary 9 48 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 pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 9 50 Brake levers Mak...

Page 63: ... necessary See page 9 28 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU28533 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front brake lever If there is free play have a Yamaha dealer check the brake system Check for correct free play in the rear brake le ver and brake pedal If the free play i...

Page 64: ... 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 Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first readin...

Page 65: ... cargo or trailer Front Recommended 35 0 kPa 0 350 kgf cm 5 0 psi Rear Recommended 30 0 kPa 0 300 kgf cm 4 4 psi Front Minimum 32 0 kPa 0 320 kgf cm 4 6 psi Rear Minimum 27 0 kPa 0 270 kgf cm 4 0 psi 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 ...

Page 66: ...er extensive tests only the tires list ed below are approved for this model by Yamaha WARNING EWB02552 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent 1 Tire tread depth Front Manufacturer model MAXXIS MU19 Size AT25 x 8 12 Rear Manufacturer model MAXXIS MU20 Size AT25 x 10 12 Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kP...

Page 67: ... 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 UB5K62E0 book Page 7 Thursday May 9 2019 2 59 PM ...

Page 68: ... pedal is applied TIP It is recommended 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 YFM700FWB The coolant temperature warning light the engine trouble warning light and the fuel le...

Page 69: ... switch Wait a few seconds before the next cranking at tempt to allow battery voltage to restore Do not crank the engine more 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 en...

Page 70: ...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 71: ...for 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 throt...

Page 72: ... 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 73: ... 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 74: ...ad 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 longer to stop Avoid making sharp turns ...

Page 75: ...8 1 8 EBU21142 RIDING YOUR ATV UB5K62E0 book Page 1 Thursday May 9 2019 2 59 PM ...

Page 76: ...on 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 77: ...hat 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 contr...

Page 78: ...NG 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 w...

Page 79: ...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 80: ...s 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 81: ...e 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 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rid er accessories an...

Page 82: ...the engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine ...

Page 83: ...rfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01512 While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles Watch carefully for other vehicles Make sure you UB5K62E0 bo...

Page 84: ... may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01532 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary to ...

Page 85: ... flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where you cannot easily be seen Mount a cau tion flag on the ATV to make you more visible Watch carefully for other vehicles EWB01552 Do not ride in areas posted no trespassing Do not ride on private property without getting permission UB5K62E0 book Page 11 Thur...

Page 86: ... release the throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident NOTICE ECB00252 Do not shift from low range to high range or vice versa without coming to a complete stop Damage to the engine or drive train may occur TURNING YOUR ATV WARNING EWB01772 Always follow proper pro...

Page 87: ...of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throt tle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV be gins to tip over to the outside whi...

Page 88: ... suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of ...

Page 89: ...r descend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could c...

Page 90: ...ore easily on extremely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble Improper braking can cause the wheels on the uphill side to come off the ground or cau se loss of trac...

Page 91: ...ither the front or rear brake because the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01633 I...

Page 92: ...t may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance grad ually steer again in the direction you wish to travel C...

Page 93: ... ride your ATV without verifying that you have regained proper braking ability WARNING Wet brakes may have reduced stopping ability which could cause loss of control EWB02622 After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Also remove the drain plugs from the storage compartment and the V belt case to drain any water...

Page 94: ...les such as lar ge 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 Air filter case check hose 1 Storage compartment drain plug 1 1 1 V belt case drain plug 1 UB5K62E0 book Page 20 Thursday...

Page 95: ...o 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 hel...

Page 96: ...n Position your weight over the front wheels for better control See page 8 12 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 12 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 recom...

Page 97: ... you discover that the ATV is going to tip over dismount on the uphill side See page 8 17 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 98: ... 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 EWB0269...

Page 99: ...cluded 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 Too...

Page 100: ... 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 101: ...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 UB5K62E0 book Page 4 Thursday May 9 2019 2 59 PM ...

Page 102: ...kills 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 if necessary Check fluid level and ATV for fluid leakage and correct if necessary Rep...

Page 103: ...r wear cracks or other damage and re place if necessary 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 11 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 12 Stabilizer bushes Check for cracks or other damage and replace if necessary 13 Rear knuckle pivots Lubricate with lithium soap based greas...

Page 104: ...ge 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 21 Final gear oil Change Check ATV for oil leakage and correct if neces sary 22 Cooling system Check coolant level and ATV for coolant leakage and correct if necessary Replace coolant Every 2 years NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Wh...

Page 105: ...s every four years and if cracked or damaged 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 ...

Page 106: ...enance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU34180 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 UB5K62E0 book Page 9 Thursday May 9 2019 2 59 PM ...

Page 107: ... 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 UB5K62E0 book Page 10 Thursday May 9 2019 2 59 PM ...

Page 108: ...ward 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 1 2 2 UB5K62E0 book Page 11 Thursday May 9 2019 2 59 PM ...

Page 109: ...el 1 Remove the seat See page 5 23 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 Hose 1 1 UB5K62E0 book Page 12 Thursday May 9 2019 2 59 PM ...

Page 110: ...ll 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 1 2 1 Screw 1 1 UB5K62E0 book Page 13 Thursday May 9 2019 2 59 PM ...

Page 111: ...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 UB5K62E0 book Page 14 Thursday May 9 2019 2 59 PM ...

Page 112: ...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 UB5K62E0 book Page 15 Thursday May 9 2019 2 59 PM ...

Page 113: ...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 UB5K62E0 book Page 16 Thursday May 9 2019 2 59 PM ...

Page 114: ... 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 9 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 115: ...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 116: ...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 117: ... 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 UB5K62E0 book Page 20 Thurs...

Page 118: ... 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 9 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 119: ... 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 UB5K62E0 book Page 22 Thursday May 9 2019 2 59 PM ...

Page 120: ...gine 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 tr...

Page 121: ...vals 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 k...

Page 122: ...l 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 b...

Page 123: ... 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 Fin...

Page 124: ...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 125: ... specified torque 8 Check the differential gear case for oil leak age If oil is leaking check for the cause EBU23473 Coolant The coolant level should be checked regularly In addition the coolant must be changed at the in tervals specified in the periodic maintenance 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 Gasket 3 ...

Page 126: ... 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 127: ... 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 128: ...der 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 9 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 UB5K62E0 book Page 31 Thursday May 9 2019 2 59 PM ...

Page 129: ...n 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 UB5K62E0 book Page 32 Thursday May 9 2019 2 59 PM ...

Page 130: ...ew 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 ...

Page 131: ... 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 132: ...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 133: ...ally 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 134: ... 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 UB5K62E0 book Page 37 Thursday May 9 2019 2 59 PM ...

Page 135: ...Apply 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 136: ... 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 137: ...he 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 torqu...

Page 138: ... with use 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 chart EBU29602 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be performed by a Yamaha dealer WARNING EWB02572 Operating with improperly servi...

Page 139: ...h allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indica tor groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared 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 64 EBU30321 Rear brake friction plates The r...

Page 140: ...age Therefore be sure to check the brake pads for wear and the brake system for leakage If the brake fluid level suddenly goes down have a Yamaha dealer check the brake sys tem before further riding WARNING EWB02721 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may allow air to enter the brake system reducing braking perfor mance Clea...

Page 141: ... 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 EBU24396 Checking the front brake lever free play 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 EBU34245 Adjusti...

Page 142: ... direction a To decrease the brake lever free play turn the adjusting bolt in direction b TIP If the specified brake lever free play could be ob tained as described above skip steps 3 8 3 Fully turn the adjusting bolt in direction a to loosen the brake cable 4 Slide the rubber cover back 1 Brake lever free play Brake lever free play 6 0 7 0 mm 0 24 0 28 in 1 1 Locknut 2 Brake lever free play adjus...

Page 143: ...lide the rubber cover to its original position 9 Tighten the locknut at the brake lever Adjusting the brake pedal free play Measure the brake pedal free play as shown If the free play is incorrect adjust it as follows 1 Remove panel G 2 Loosen the locknut 1 Brake cable adjuster locknut 2 Brake lever free play adjusting nut 3 Rubber cover 2 3 1 a b 1 Brake pedal free play Brake pedal free play 12 0...

Page 144: ...knut 5 Install the panel 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 free play adjusting nut 2 Locknut 2 a b 1 1 Front axle boot each side 1 1 UB5K62E0 book Page 47 Thursday May 9 2019 2 59...

Page 145: ... adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EBU24905 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it 1 Rea...

Page 146: ...g 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 EBU28712 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary Front brake lever Recommended lubric...

Page 147: ...l pivot remove panel G See page 9 9 EBU24964 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 smooth ly have a Yamaha dealer check the wheel hub bearings Recommended lubricant Lithium soap based grease UB5K62E0 book Page 50 Th...

Page 148: ...enance 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 chart Recommended lubricant Lithium soap based grease UB5K62E0 book Page 51 Thursday May 9 2019 2 59 PM ...

Page 149: ...g the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe riodic maintenance chart YFM700FWB YFM700FWBD YFM70KPAL 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 UB5K62E0 book Page 52 Thursday May 9 2019 2 59 PM ...

Page 150: ...ealer WARNING EWB02161 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cau se severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Fl...

Page 151: ...the main switch must be off and the negative lead must be disconnected be fore the positive lead ECB01002 5 Pull the battery out of its compartment 1 Front carrier 2 Carrier bolt upper 1 Carrier bolt under the fenders 2 Carrier bolt lower 1 2 2 1 2 2 1 1 Battery holding plate 2 Nut 3 Negative battery lead black 4 Positive battery lead red 1 2 4 3 UB5K62E0 book Page 54 Thursday May 9 2019 2 59 PM ...

Page 152: ...ge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00942 Always keep the battery charged Storing the 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 ...

Page 153: ...charge the battery before installing it EBU30525 Replacing a fuse 1 Positive battery lead red 2 Negative battery lead black 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 2 1 Fuse box 2 Main fuse 3 EPS fuse equipped models 4 Fuel injection system spare fuse 5 Fuel injection syst...

Page 154: ...he main switch when checking or replacing a fuse 1 Headlight fuse 2 Signaling system fuse 3 Radiator fan motor fuse 4 Ignition fuse 5 Auxiliary DC jack fuse 6 Spare fuse 1 2 3 4 5 6 1 Headlight fuse 2 Radiator fan motor fuse 3 Signaling system fuse 4 Ignition fuse 5 Four wheel drive motor fuse 6 Auxiliary DC jack fuse 7 Spare fuse 1 2 3 4 5 6 7 UB5K62E0 book Page 57 Thursday May 9 2019 2 59 PM ...

Page 155: ...which could lead to a fire EWB02173 4 Turn on the main switch and start the engine 5 If the fuse immediately blows again have a Yamaha dealer check the vehicle 6 Install the panel Specified fuses Main fuse 40 0 A Headlight fuse 10 0 A YFM700FWB 15 0 A YFM700FWBD YFM70KPAL Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A YFM700FWBD YFM70KPAL Signaling system fuse 10 0 A Auxiliary DC jack fus...

Page 156: ...eft and right headlight bulbs 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the bulb cover by pulling it off 3 Remove the socket by pushing it in and turn ing it counterclockwise 1 Cover at the rear of the headlight 1 1 Bulb cover 1 Socket 1 1 UB5K62E0 book Page 59 Thursday May 9 2019 2 59 PM ...

Page 157: ... socket by pushing it in and turning it clockwise 7 Install the bulb cover and the cover at the rear of the headlight NOTICE Make sure the bulb cover is securely fitted over the sock et and seated properly ECB03320 8 Adjust the headlight beam if necessary Handlebar mounted light bulb YFM700FWBD YFM70KPAL 1 Remove the handlebar mounted light cover by removing the quick fasteners 2 Remove the bulb c...

Page 158: ...rency 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 6 Install the socket by pushing it in and turning it clockwise 7 Install the bulb cover NOTICE Make sure the bulb cover is securely fitted over the socket and seated properly ECB03320 1 Bulb cover 1 Socket 1 1 1 Do not touch the glass par...

Page 159: ...ting 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 Handlebar mounted light cover 1 1 Headlight beam adjusting screw b a 1 UB5K62E0 book Page 62 Thursday May 9 2019 2 59 PM ...

Page 160: ...1 Remove the brake tail light bulb holder to gether with the bulb by turning it counter clockwise 2 Remove the burnt out bulb by pushing it in and turning it counterclockwise 1 Handlebar mounted light beam adjusting screw b a 1 1 Brake tail light bulb holder 1 Brake tail light bulb 1 1 UB5K62E0 book Page 63 Thursday May 9 2019 2 59 PM ...

Page 161: ...TV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU36243 Installing a wheel 1 Install the wheel with the arrow mark pointing in the forward rotating direction of the wheel and then install the wheel nuts TIP For B5KJ B5KK B6KA be sure to install the nuts with their tapered side towards the wheel 1 Wheel nut 1 1 1 Arrow mark 2 Forward rotating direc...

Page 162: ...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 explode causing se...

Page 163: ...ve the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Check the compression Dry Wet Operate the electric starter Have a Yamaha dealer check the ATV The engine does not start Check the ignition Operate the electric starter 2 Battery The engine turns over qu...

Page 164: ...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 165: ...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 166: ... 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 s...

Page 167: ...10 3 10 8 Remove the battery and fully charge it See page 9 53 UB5K62E0 book Page 3 Thursday May 9 2019 2 59 PM ...

Page 168: ...701 lb B5KJ 323 0 kg 712 lb B5KN B5KS B5KV 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 79 0 dB A at 3125 r min YFM700FWB YFM700FWBD Uncertainty of measurement 0 6 dB A YFM700FWB YFM700FWBD Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s YFM700FWB YFM700FWBD Uncertainty of measurement 0 0 ...

Page 169: ...W 40 15W 40 20W 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 Quantity 0 52 L 0 55 US qt 0 46 Imp qt Differential gear oil Type Yamaha Friction Modified Plus Shaft Dr...

Page 170: ...4 0 L 1 06 US gal 0 88 Imp gal Throttle body ID mark B4F100 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 9 545 41 21 x 24 18 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 gea...

Page 171: ...m 4 0 psi 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 Rear wheel Rim size 12 x 7 5 AT Front brake Type Hydraulic disc brake Rear brake Type Mechanical wet multiple disc brake Brake fluid Specified brake fluid DOT 4 F...

Page 172: ...ng light LED YFM700FWB Reverse indicator light LED Coolant temperature warning light LED Park indicator light LED Four wheel drive indicator light 1 7 W YFM700FWB Engine trouble warning light LED High range indicator light LED YFM700FWBD YFM70KPAL Low range indicator light LED YFM700FWBD YFM70KPAL Differential gear lock indicator light LED YFM700FWBD YFM70KPAL EPS warning light LED YFM700FWBD YFM7...

Page 173: ...k 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 and risk EBU38670 CO2 emissi...

Page 174: ... 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 engin...

Page 175: ...eaning 10 1 Coolant 6 3 9 28 Coolant temperature warning light 5 3 D Differential gear lock indicators YFM700FWBD YFM70KPAL 5 5 Differential gear oil 6 3 9 26 Drive lever 2WD 4WD YFM700FWB 5 17 Drive select lever 5 20 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 19 Engine stop ...

Page 176: ...ol kit 9 2 P Panels removing and installing 9 9 Park indicator light 5 2 Parking 7 4 Parking on a slope 7 5 Part locations 4 1 R Rear brake adjusting the lever pedal free play 9 44 Rear knuckle pivots lubricating 9 51 Reverse indicator light 5 2 Riding your ATV 8 1 S Safety information 3 1 Seat 5 23 Shock absorber assemblies adjusting the front and rear YFM700FWBD YFM70KPAL 5 26 Spark arrester cle...

Page 177: ...13 V belt case drain plug 9 40 Vehicle identification number 1 1 W Wheel hub bearings checking 9 50 Wheel installing 9 64 Wheel removing 9 64 Y Yamalube 9 23 UB5K62E0 book Page 3 Thursday May 9 2019 2 59 PM ...

Page 178: ... 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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Yamaha KODIAK 2019, Owner'S Manual

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Summary of Contents for KODIAK 2019

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