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Yamaha KODIAK 450, Owner'S Manual, Page: 8 / 190

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Yamaha KODIAK 450 Owner'S Manual Download Page 8

PERIODIC MAINTENANCE AND 
ADJUSTMENT.................................. 8-1

Owner’s manual and tool kit............ 8-1
Periodic maintenance/

lubrication ...................................... 8-3

Panel removal and installation ........ 8-5
Engine oil and oil filter cartridge .... 8-12
Final gear oil .................................. 8-17
Differential gear oil......................... 8-19
Cooling system.............................. 8-21
Changing the coolant .................... 8-23
Axle boots...................................... 8-26
Spark plug inspection .................... 8-27
Air filter element cleaning .............. 8-29
V-belt cooling duct check hose ..... 8-32
V-belt case drain plug.................... 8-33
Spark arrester cleaning ................. 8-33
Carburetor adjustment................... 8-35
Idle speed adjustment ................... 8-35
Valve clearance adjustment .......... 8-36
Throttle lever adjustment............... 8-37
Front brake pad check .................. 8-38
Rear brake pad check ................... 8-38

Inspecting the brake fluid level ......8-39
Brake fluid replacement .................8-41
Front brake lever free play.............8-41
Rear brake lever adjustment .........8-42
Brake pedal position 

adjustment ...................................8-43

Adjusting the rear brake light 

switch ...........................................8-44

Cable inspection and 

lubrication.....................................8-45

Brake lever and brake pedal 

lubrication.....................................8-45

Wheel removal ...............................8-46
Wheel installation...........................8-47
Battery............................................8-48
Battery maintenance......................8-49
Fuse replacement ..........................8-49
Replacing a headlight bulb ............8-51
Headlight beam adjustment...........8-54
Tail/brake light bulb 

replacement .................................8-54

Troubleshooting .............................8-55
Troubleshooting charts ..................8-56

8

U5ND11.book  Page 3  Wednesday, April 30, 2003  1:52 PM

Summary of Contents for KODIAK 450

Page 1: ......

Page 2: ......

Page 3: ...t safety information It provides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING...

Page 4: ...bol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer U...

Page 5: ...ll applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU01067 YFM450FAS OWNER S MANUAL 2003 by Yamaha Motor Corporation U S A 1st edition April 2003 All rights reserved Any reprinting or unauthorized use without the written permission of U5ND11 book Page 2 We...

Page 6: ...ation number 3 2 Vehicle identification number 3 3 1 2 3 Indicator and warning lights 4 2 Fuel gauge 4 4 Speedometer unit 4 4 Handlebar switches 4 6 Throttle lever 4 13 Speed limiter 4 14 Front brake lever 4 15 Brake pedal and rear brake lever 4 15 Drive select lever 4 16 Recoil starter 4 16 Fuel tank cap 4 17 Fuel cock 4 18 Starter choke 4 19 Seat 4 20 Storage compartment 4 21 Front carrier 4 22 ...

Page 7: ...ng a cold engine 6 1 Starting a warm engine 6 3 Parking on a slope 6 9 Accessories and loading 6 10 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 22 Climbing uphill 7 24 Riding downhill 7 30 Crossing a slope 7 32 Crossing through shallow water 7 34 Riding over rough terrain 7 37 Sliding and skidding 7 38 Wha...

Page 8: ...k hose 8 32 V belt case drain plug 8 33 Spark arrester cleaning 8 33 Carburetor adjustment 8 35 Inspecting the brake fluid level 8 39 Brake fluid replacement 8 41 Front brake lever free play 8 41 Rear brake lever adjustment 8 42 Brake pedal position adjustment 8 43 Adjusting the rear brake light switch 8 44 Cable inspection and lubrication 8 45 Brake lever and brake pedal lubrication 8 45 Wheel re...

Page 9: ...1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 9 10 11 12 13 14 U5ND11 book Page 4 Wednesday April 30 2003 1 52 PM ...

Page 10: ...EBU00464 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5ND11 book Page 1 Wednesday April 30 2003 1 52 PM ...

Page 11: ...fficult to read or comes off a replacement label is available from your Yamaha dealer 3 1 2 Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an accident Never exceed the maximum front cargo limit of 40kg 88 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4877 00 WARNING U5ND11 book Page 2 Wednesday...

Page 12: ...ever exceed the maximum rear cargo limit of 80kg 176 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4897 00 WARNING PULLING LOAD 4900 N 5 0 0 k g f 1102 l b f TONGUE WEIGHT 147 N 1 5 k g f 33 l b f 5ND F151K 00 MAXIMUM LOADING LIMIT MAXIMUM LOADING LIMIT 6 U5ND11 book Page 3 Wednesday April 30 2003 1 52 PM ...

Page 13: ...this ATV if you are under the age of 16 increases your chance of severe injury or death Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control WARNING U5ND11 book Page 4 Wednesday April 30 2003 1 52 PM ...

Page 14: ...t proper training or instruction Take a Training Course Begin ners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc Never allow a child under age 16 to operate an ...

Page 15: ... use it to make sure it is in safe operating condition Al ways follow the inspection and maintenance procedures and schedules described in this man ual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Ne...

Page 16: ...the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if p...

Page 17: ...ure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly di...

Page 18: ...ames or other sources of ignition such as the pilot When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gas...

Page 19: ... a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation U5ND11 book Page 6 Wednesday April 30 2003 1 52 PM ...

Page 20: ...ng preload adjusting ring 8 V belt case 9 Brake pedal 10 Front shock absorber assembly spring preload adjusting ring 13 Fuses 14 Tail brake light 15 V belt cooling duct check hose 16 Coolant reservoir 17 Oil filter cartridge 18 Engine oil dipstick 19 Rear brake lever 20 Left handlebar switches 21 Starter choke 22 Drive select lever 23 Speedometer unit 24 Main switch 25 Fuel tank cap 26 Auxiliary D...

Page 21: ... spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number U5ND11 book Page 2 Wednesday Apr...

Page 22: ...icle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label U5ND11 book Page 3 Wednesday April 30 2003 1 52 PM ...

Page 23: ...in switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights taillight and meter lighting come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position 1 Main switch U5ND11 book Page 1 Wednesday April 30 2003 1 52 PM ...

Page 24: ...ck indicator light DIFF LOCK This indicator light and the differential gear lock indicator in the display come on when the differential gear lock switch is set to the 4WD LOCK position NOTE _ When the switch is set to LOCK the differ ential gear lock indicator light will flash until the differential gear is locked _ EBU11220 Low range indicator light L This indicator light comes on when the drive ...

Page 25: ...r light comes on when the drive select lever is in the P park position EBU00860 Coolant temperature warning light When the coolant temperature reaches a specified level this light comes on to warn CAUTION _ The engine may overheat if the ATV is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause...

Page 26: ...NOTE _ If the machine runs out of fuel move the fuel cock lever to the RES position Approxi 1 Speedometer 2 Odometer Tripmeter A Tripmeter B 3 Clock Hour meter 4 TRIP ODO button 5 Clock Hour button 6 H button 7 M button EBU11321 Speedometer unit The speedometer unit is equipped with the following a speedometer which shows the riding U5ND11 book Page 4 Wednesday April 30 2003 1 52 PM ...

Page 27: ...and B in the fol lowing order ODO TRIP A TRIP B ODO To reset a tripmeter select it by pushing the TRIP ODO button and then push the TRIP ODO button for at least three seconds The tripmeters can be used to estimate the dis tance that can be traveled with a full tank of fu el This information will enable you to plan future fuel stops NOTE _ Holding in the TRIP ODO button and then turning the key to ...

Page 28: ... the clock starts flashing 2 Set the hours by pushing the H button 3 Set the minutes by pushing the M but ton 4 Push the button and then re lease it to start the clock EBU00053 Handlebar switches 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE EBU12510 Light switch OFF Set the switch to to turn on the low U5ND11 book Page 6 Wednesday April 30 2003 1 52 PM ...

Page 29: ...e that the engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is set to EBU00607 Start switch The starter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engin...

Page 30: ...is switch to override the 4WD LOCK speed limiting function See page 4 11 for a detailed explanation about the differential NOTE _ If the digits of the speedometer appear as shown when the switch is NOT being pushed this could indicate a malfunction in the electri cal system In this case take the ATV to a Yamaha dealer at the first opportunity _ U5ND11 book Page 8 Wednesday April 30 2003 1 52 PM ...

Page 31: ...iding too fast while the ATV is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the ATV The amount of effort is more the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in 4WD...

Page 32: ...m 2WD to 4WD or from 4WD to 4WD LOCK DIFF LOCK or vice versa while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD and in 4WD LOCK in some circumstances Changing from 2WD to 4WD or from 4WD to 4WD LOCK or vice versa while moving may cause the ATV to unexpectedly handle differently This could distract the operator and in crease the risk of losing control and an acci...

Page 33: ... speedometer unit display To change from 4WD to 2WD stop the ATV 1 Differential gear lock switch LOCK 4WD 2 Lever Differential gear lock switch LOCK 4WD To lock the differential gear in 4WD make sure the on command four wheel drive switch is set to 4WD stop the ATV move the lever to po sition b and then set the switch to LOCK When the differential gear is locked the differ U5ND11 book Page 11 Wedn...

Page 34: ...ed to 35 km h 22 mph However if conditions require full engine power to be available push and hold the override switch to dis able the 4WD LOCK speed limiter See WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the ATV The amount of effort is more the faster you go...

Page 35: ...ine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever befor...

Page 36: ...ew a 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to 3 5 mm ...

Page 37: ...ront brake lever is located on the right handlebar Pull it toward the handlebar to ap ply the front brake 1 Front brake lever EBU00732 Brake pedal and rear brake lever 1 Brake pedal U5ND11 book Page 15 Wednesday April 30 2003 1 52 PM ...

Page 38: ...rk positions Refer to page 6 4 for the drive select lever operation 1 Drive select lever EBU00855 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt Then pull forcefully being careful not to pull the rope all the way out 1 Recoil starter U5ND11 book Page 16 Wednesday April 30 2003 1 52 PM ...

Page 39: ... Starting the engine without setting the drive select lever to the park position P WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Set the drive select lever to the park po sition before starting the engine U5ND11 book Page 17 Wednesday April 30 2003 1 52 PM ...

Page 40: ...unning ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON position 1 Arrow mark pointing to OFF OFF Position ON Position U5ND11 book Pa...

Page 41: ...ir fuel mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 RES Position U5ND11 book Page 19 Wednesday April 30 2003 1 52 PM ...

Page 42: ... rear 1 Seat 2 Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE _ Make sure that the seat is securely fitted _ 1 Projection 2 2 Seat holder 2 U5ND11 book Page 20 Wednesday April 30 2003 1 52 PM ...

Page 43: ...artment be sure to wrap them in a plas tic bag so that they will not get wet When washing the ATV be careful not to let any wa ter enter the storage compartment NOTE _ There is a check hose at the bottom of the storage compartment If any water collects in this hose remove the hose empty it and then install it _ 1 Storage compartment U5ND11 book Page 21 Wednesday April 30 2003 1 52 PM ...

Page 44: ... and riding conditions Adjust the spring preload as follows To increase the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring Maximum load limit 40 kg 88 lb Maximum load limit 80 kg 176 lb U5ND11 book Page 22 Wednesday April 30 2003 1 52 PM ...

Page 45: ...aximum hard WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set ting U5ND11 book Page 23 Wednesday April 30 2003 1 52 PM ...

Page 46: ...ease the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ 1 Special wrench Standard position 2 1 Minimum soft 5 Maximum hard U5ND11 book Page 24 Wednesday April 30 2003 1 52 PM ...

Page 47: ...liary DC jack is not being used cover it with the cap CAUTION _ Do not use accessories requiring more than the above maximum capac ity This may overload the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may be come difficult Do not use an automotive cigarette Maximum rated ...

Page 48: ...1 Auxiliary DC jack EBU00112 U5ND11 book Page 26 Wednesday April 30 2003 1 52 PM ...

Page 49: ...el level Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 6 8 12 8 16 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 7 8 21 8 26 Final gear oil and differential gear oil Check for leakage 5 6 8 17 8 21 Throttle Check for proper throttle cable operation and free play 5 7 8 37 Wheels and tires Check tire pressure wear an...

Page 50: ...edal They should move smoothly and there should be a firm feeling when the brakes are applied If not have a Yamaha dealer inspect the brake system Brake fluid level WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper ating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV eac...

Page 51: ... are working properly If the brakes do not provide proper braking per formance inspect the brake pads for wear See pages 8 38 8 39 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with t...

Page 52: ...signed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 15 L 3 3 Imp gal 3 96 US gal Reserve...

Page 53: ...AZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the...

Page 54: ...ke sure that no foreign material en ters the crankcase _ EBU00493 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 17 8 19 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used EBU00678 Differential gear oil Make sure the...

Page 55: ...s CAUTION _ Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water _ EBU01083 Throttle lever Check to see that the throttle lever operates Coolant reservoir capacity WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HO...

Page 56: ... of all switches Have a Yamaha dealer repair as necessary for proper operation EBU00157 Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of acci dent HOW TO AVOID THE HAZARD 1...

Page 57: ... could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 22 kPa 0 22 kgf cm2 3 2 psi Rear 22 kPa 0 22 kgf cm2 3 2 psi 4 Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fas...

Page 58: ...reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifica tions ACE 02EACE 02E 1 Low pressure tire gauge Recommended pressure Minimum Maximum Front 25 kPa 0 25 kgf cm2 3 6 psi 22 kPa 0 22 kgf cm2 3 2 psi 28 kPa 0 28 kgf cm2 4 0 psi 25 kPa 22 kPa 28 kPa U5ND11 book Page 10 Wednesday April 30 2003 1 52 P...

Page 59: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit U5ND11 book Page 11 Wednesday April 30 2003 1 52 PM ...

Page 60: ...HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW TO AVOID THE HAZARD When ridin...

Page 61: ...tral or park before starting the engine 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warm Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 6 Completely close ...

Page 62: ...to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine CAUTION See the Engine break in section prior to operating the engine for the first time EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used The throttle should be opened...

Page 63: ...may be damaged _ Shifting Neutral to High and High to Low 1 Bring the machine to a complete stop and return the throttle lever to the closed position 2 Apply the brakes then shift by moving the drive select lever along the shift guide NOTE Make sure that the drive select lever is com 1 Drive select lever 3 Open the throttle lever gradually U5ND11 book Page 4 Wednesday April 30 2003 1 52 PM ...

Page 64: ...ear brake pedal 3 Shift from neutral to reverse or from re verse to park and vice versa by moving the drive select lever along the shift guide 1 Drive select lever NOTE _ When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the reverse indicator light electrical cir cuit Due to the synchronizing mechanism in the engine the light may ...

Page 65: ...roperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slow ly U5ND11 book Page 6 Wednesday April 30 2003 1 52 PM ...

Page 66: ... might result in ex cessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this per...

Page 67: ...l throttle at any time After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00612 Parking When parking stop the engine and shift the drive select lever into the park position then turn the fuel cock to the OFF position U5ND11 book Page 8 Wednesday April 30 2003 1 52 PM ...

Page 68: ...HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the machine transversely across the in cline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easil...

Page 69: ... genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object attac...

Page 70: ...rying cargo and towing a trail er include the tongue weight in the maxi mum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause...

Page 71: ... hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed an...

Page 72: ...EBU14480 WARNING _ Indicates a potential hazard that could result in serious injury or death U5ND11 book Page 13 Wednesday April 30 2003 1 52 PM ...

Page 73: ...7 1 Riding Your ATV U5ND11 book Page 1 Wednesday April 30 2003 1 52 PM ...

Page 74: ...U5ND11 book Page 2 Wednesday April 30 2003 1 52 PM ...

Page 75: ...riate for all types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable begin to ride be sure you have read this Own er s Manual completely and understand the operation of the controls Pay particular atten tion to the...

Page 76: ...time Take the time to learn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills lea...

Page 77: ...menda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc U5ND11 book Page 5 Wednesday April 30 2003 1 52 PM ...

Page 78: ...N Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers U5ND11 book Page 6 Wednesday April 30 2003 1 52 PM ...

Page 79: ...ccident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleev...

Page 80: ...RD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV U5ND11 book Page 8 Wednesday April 30 2003 1 52 PM ...

Page 81: ... is in safe op erating condition Always follow the inspection and main WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use the size a...

Page 82: ... mum Turning in the adjusting screw limits the maximum engine power available and de creases the maximum speed of the ATV Turning the adjusting screw in decreases top speed and turning it out increases top speed See page 4 14 for details WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ...

Page 83: ...ler hitch Pulling load 500 kg 1 102 lb Total weight of trailer and cargo Tongue weight 15 kg 33 lb WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely a...

Page 84: ...ven one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation U5...

Page 85: ... POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off U5ND11 book Page 13 Wednesday April 30 2003 1 52 PM ...

Page 86: ...ause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed U5ND11 book Page 14 Wednesday April 30 2003 1 52 PM ...

Page 87: ...ARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it U5ND11 book Page 15 Wednesday...

Page 88: ...this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets U5ND11 book Page 16 Wednesday April 30 2003 1 52 PM ...

Page 89: ...rating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways U5ND11 book Page 17 Wednesday April 30 2003 1 52 PM ...

Page 90: ...ENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturn ing or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar terrain Always be U5ND11 book Page 18 Wednesday April 30 2003 1 52 PM ...

Page 91: ... vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain U5ND11 book Page 19 Wednesday April 30 2003 1 52 PM ...

Page 92: ...r hitch Do not ride in areas posted no trespassing Do not ride on private property without getting permission WARNING WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles U5ND11 book Page 20 Wednesday April 30 2003 1 52 PM ...

Page 93: ... riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling shift the drive select le ver to the low position L or the high position H 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 ...

Page 94: ... approach a curve slow down and be gin to turn the handlebars in the desired direc tion As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a HOW TO AVOID THE HAZARD Always follow pro...

Page 95: ...proper riding procedures such as abrupt throttle 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 begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Av...

Page 96: ...tant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small h...

Page 97: ...s described in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards An obstacle a sharp drop or another vehicle or person could be on the other side of the hill U5ND11 book Page 25 Wednesday April 30 2003 1 52 P...

Page 98: ...NTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible U5ND1...

Page 99: ... hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV U5ND11 book Page 27 Wednesday April 30 2003 1 52 PM ...

Page 100: ...by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake ped al will brake the wheels on the downhill side the front and rear brakes gradually or dis mount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a...

Page 101: ...shift to the parking position P 4WD or 4WD LOCK Apply both front and rear brakes gradually When fully stopped shift to the parking position P Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu al U5ND11 book Page 29 Wednesday April 30 2003 1 52 PM ...

Page 102: ... also cause a loss of traction When this ATV is in 4WD or 4WD LOCK all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden application of either the front or rear brake be cause the ...

Page 103: ...ng down hills as described in this Own er s Manual Note a special technique is required when braking as you go down a hill HOW TO AVOID THE HAZARD Always check the terrain carefully be fore you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that U5ND11 book Page 31 Wednesday April 30 2003 1 52 PM ...

Page 104: ... up hill 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 WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill unti...

Page 105: ...U5ND11 book Page 33 Wednesday April 30 2003 1 52 PM ...

Page 106: ...ry or up set the ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to le...

Page 107: ...d water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hose and the storage compartment check hose Also remove the V belt case drain plug to drain any water that may have accumulated Wash the ATV in fresh water if it has been operated in salt water or muddy conditions _ U5ND11 book Page 35 Wednesday April 30 2003 ...

Page 108: ...1 V belt cooling duct check hose left front side of ATV 1 Storage compartment check hose U5ND11 book Page 36 Wednesday April 30 2003 1 52 PM ...

Page 109: ...l and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper procedur...

Page 110: ...eels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide U5ND11 book Page 38 Wednesday April 30 2...

Page 111: ...trol may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious i...

Page 112: ...necessary gradually let off the throttle and or steer to the outside of the turn See pag If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerat ing is not recommended until you have cor rected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for war...

Page 113: ...ver that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water 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 un til you have regained adequate braking ability See ...

Page 114: ...anual and tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it on the bottom of the seat as shown Put the own er s tool kit and low pressure tire gauge under the seat WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or ca...

Page 115: ...ur machine to a Yamaha dealer to check the torque settings and adjust them as neces sary _ WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er insta...

Page 116: ...filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check and adjust idle speed starter operation Adjust if necessary Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary Spark arrester Clean Fuel line Check fuel hose for cracks ...

Page 117: ...e in Adjust if necessary Drive shaft universal joint Lubricate with lithium soap based grease Engine mount Check for cracks or damage Axle boots Check operation Replace if damaged Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check operation Adjust headlight beams ITEM ROUTINE Whichever comes first INITIAL EVERY mile km 200 320 750 1 200 1...

Page 118: ... need to be removed to perform some of the maintenance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 1 Panel A 2 Panel B 1 Panel C 2 Panel D 3 Panel E 4 Panel F U5ND11 book Page 5 Wednesday April 30 2003 1 52 PM ...

Page 119: ...EBU00700 Panel A D To remove 1 Remove the seat 2 Pull outward on the areas shown and then pull upward U5ND11 book Page 6 Wednesday April 30 2003 1 52 PM ...

Page 120: ...To install 1 Place the panel in its original position 2 Install the seat U5ND11 book Page 7 Wednesday April 30 2003 1 52 PM ...

Page 121: ...e bolt and then take the panel off To install Place the panel in the original position and in stall the bolt CAUTION _ When installing the panel be sure not to pinch the cables or wires _ U5ND11 book Page 8 Wednesday April 30 2003 1 52 PM ...

Page 122: ...rrier bolts 1 Carrier bolt 4 top 2 Remove the carrier bolts under the fend ers and then take the carrier off 1 Bolt 2 under fenders 3 Remove the quick fasteners and pull the panel upward to remove U5ND11 book Page 9 Wednesday April 30 2003 1 52 PM ...

Page 123: ...arrier bolts and then tight en all bolts to the specified torques EBU01013 Panel E To remove Remove the bolts and then take the panel off To install Place the panel in the original position and then install the bolts 1 Panel E 2 Bolt 3 Tightening torque Carrier bolt top 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt under fenders 7 Nm 0 7 m kgf 5 ft lbf U5ND11 book Page 10 Wednesday April 30 2003 1 52 PM ...

Page 124: ...EBU00638 Panel F To remove Pull outward on the areas shown 1 Panel F To install Place the panel in its original position U5ND11 book Page 11 Wednesday April 30 2003 1 52 PM ...

Page 125: ...val and installation proce dures 2 Place the ATV on a level surface 3 Start the engine warm it up for several minutes and then turn it off 4 Wait a few minutes until the oil settles 5 Remove the engine oil filler cap and wipe off the dipstick with a clean rag 1 Engine oil filler cap 6 Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level ...

Page 126: ...nstall the panel To change the engine oil with or without oil filter cartridge replacement 1 Remove panel F See page 8 11 for panel removal and installation proce dures 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to col lect the used oil and then remove the en gine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from...

Page 127: ...proce dures 6 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter wrench NOTE _ An oil filter wrench is available at a nearby Yamaha dealer _ 7 Apply a light coat of engine oil to the O ring of the new oil filter cartridge NOTE _ Make sure the O ring is seated properly _ U5ND11 book Page 14 Wednesday April 30 2003 1 52 PM ...

Page 128: ... with a torque wrench 1 Torque wrench 9 Install panel E 10 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 16 ft lbf U5ND11 book Page 15 Wednesday April 30 2003 1 52 PM ...

Page 129: ...terial en 12 Start the engine and warm it up for seve ral minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 13 Turn the engine off and then check the oil level and correct it if necessary 14 Install panel F Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 2 3 L 2 0 Imp qt 2 4 US q...

Page 130: ...e oil level should be at the brim of the filler hole _ 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 1 Final gear oil 2 Final gear oil filler bolt 3 Correct level CAUTION _ Be sure no foreign material enters the final gear case _ 4 Install the oil filler bolt E 8 fm Page 17 Thursday May 8 2003 2 19 PM ...

Page 131: ...Place a container under the final gear case to collect the used oil 4 Remove the oil filler bolt and the drain 1 Final gear oil drain bolt 5 Install the drain bolt and then tighten it to the specified torque 6 Add the recommended final gear oil to Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 16 ft lbf E 8 fm Page 18 Thursday May 8 2003 2 19 PM ...

Page 132: ...r oil measurement 1 Place the machine on a level surface 2 Remove the differential gear oil filler bolt and check the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the recommend ed type to raise it to the specified level 1 Differential gear oil Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 23 L 0 2 Imp qt 0 24 US qt Tightening t...

Page 133: ...tial gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil 1 Differential gear oil drain bolt 4 Install the differential gear oil drain bolt and tighten it to the specified torque 5 Fill the differential gear case with the rec Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 ft lbf U5ND11 book Page...

Page 134: ...0 Cooling system 1 Place the ATV on a level surface 2 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine tem perature NOTE _ The coolant should be between the minimum and maximum level marks _ Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 23 L 0 2 Imp qt 0 24 US qt U5ND11 book Page 21 Wednesday April 30 2003 1 52 PM ...

Page 135: ...the engine You may use soft water if you can not get distilled water _ NOTE _ If water is added have a Yamaha dealer check the antifreeze content of the cool ant as soon as possible The radiator fan operation is completely automatic It is switched on or off accord ing to the coolant temperature in the radi ator _ If your ATV overheats see page 8 57 for de tails Coolant reservoir capacity up to the...

Page 136: ...o prevent coolant from spilling on the foot rest WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag over the cap Allow any re maining pressure to escape before com...

Page 137: ...emove the radiator cap 1 Radiator cap 6 Remove panel D See pages 8 6 8 7 for panel removal and installation proce dures 7 Remove the coolant reservoir cap 8 Disconnect the hose on the coolant res ervoir side and then drain the coolant from the coolant reservoir U5ND11 book Page 24 Wednesday April 30 2003 1 52 PM ...

Page 138: ...rvoir to the maximum level mark and then install the reservoir cap and panel D 13 Pour the recommended coolant into the radiator until it is full and then install the radiator cap Tightening torque Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze and water mixing ratio 1 1 Total amount 1 3 L 1 1 Imp qt 1 4 US qt Coolant ...

Page 139: ...adiator If it is low add more coolant until it reaches the top of the radiator 15 Check for coolant leakage NOTE _ If any leakage is found have a Yamaha deal er check the cooling system _ 16 Install the panels and the front carrier EBU00862 Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by a Yamaha dealer 1 Axle boot 2 each side U5ND11 book Page ...

Page 140: ...park plug cap 1 Spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1 Spark plug wrench Inspection The spark plug is an important engine compo nent and is easy to inspect The condition of the spark plug can indicate the condition of the engine U5ND11 book Page 27 Wednesday April 30 2003 1 52 PM ...

Page 141: ...ther deposits are excessive you should replace the spark plug with the specified plug Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification a Spark plug gap 2 Clean the gasket surface Wipe off any grime from the threads 3 Install the spark plug and tighten it to the specified torque Specified spark plug DR8EA NGK Tightening torque Spa...

Page 142: ...orque as soon as possible _ 4 Install the spark plug cap 5 Install the panel EBU11331 Air filter element cleaning NOTE _ There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seat See page 4 20 for U5ND11 book Page 29 Wednesday April 30 2003 1 ...

Page 143: ...ase cover 3 Remove the air filter element and then remove it from its frame 1 Air filter element frame 2 Air filter element 4 Wash the element gently but thoroughly in solvent U5ND11 book Page 30 Wednesday April 30 2003 1 52 PM ...

Page 144: ...e air filter element should be wet but not dripping _ 8 Pull the air filter element over its frame 9 Install the air filter element assembly 10 Install the air filter case cover 11 Install the seat WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZAR...

Page 145: ...ight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine _ CAUTION _ Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration without the air filter element will af EBU06411 V belt cooling duct check hose If dust or water collects in...

Page 146: ...after re moving the plug have a Yamaha dealer in spect the ATV as the water may affect other engine parts _ EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the bolts 2 Remove the tailpipe by pulling it out of the muffler 1 Bolt 3 3 Tap the tailpipe lightly and then use a U5ND11 book Page 33 Wednesday April 30 2003 1 52 PM ...

Page 147: ... exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool pri or to touching exhaust components Do not start the engine when cleaning the exhaust system U5ND11 book Page 34 Wednesday April 30 2003 1 52 PM ...

Page 148: ...c tory after many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result EBU12580 Idle speed adjustment NOTE _ A diagnostic tachometer must be used for this procedure _ 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine ...

Page 149: ... tion b to decrease the engine speed EBU00303 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clear ance must be adjusted regularly This adjust ment however should be left to a professional Yamaha service technician Specified idle speed 1 450 1 550 r min U5ND11 book Page 36 Wednesday April 30 20...

Page 150: ...ing speed before adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle le ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut a Throttle lever free play U5ND11 book Page 37 Wednesday April 30 2003 1 52 PM ...

Page 151: ...k the EBU06212 Rear brake pad check Check the brake pads for damage or wear Wear indicator grooves are provided on the brake pads These indicators allow checking of brake pad wear without disassembling the brake Check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared ask a Yamaha dealer to replace the pads as a set U5ND11 book P...

Page 152: ...e Before riding check that the brake fluid is above the minimum level mark and replenish when necessary A low brake fluid level may indicate worn brake pads and or brake sys tem leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage The rear brake fluid master cylinder reservoir is located under panel C See pages 8 9 8 10 for panel re mova...

Page 153: ...ng leakage and poor brake per formance Refill with the same type of brake fluid Mix ing fluids may result in a harmful chemical reaction and lead to poor brake perfor mance Be careful that water does not enter the master cylinder reservoirs when refilling Water will significantly lower the boiling point of the fluid and may result in vapor FRONT REAR Recommended brake fluid DOT 4 U5ND11 book Page ...

Page 154: ...maha service personnel Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years EBU11870 Front brake lever free play The front brake lever should have a free play of zero mm zero in at the lever end If not have a Yamaha dealer check the brake sys tem a Front b...

Page 155: ... free play WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replace...

Page 156: ...AZARD Operating with improperly serviced or adjusted brake WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is cor rect Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re U5...

Page 157: ...ke light switch as follows 1 Remove panel B See page 8 8 for pan el removal and installation procedures 2 Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjust ing nut in direction b 3 Install the panel 1 Rear brake light switch 2 Adjusting nut U5N...

Page 158: ...POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Recommended lubricant Lithium soap based grease all purpose grease U5...

Page 159: ...Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 U5ND11 book Page 46 Wednesday April 30 2003 1 52 PM ...

Page 160: ...ered side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel _ 2 Lower the ATV so that the wheel is on the ground 1 Tapered nut 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf U5ND11 book Page 47 Wednesday April 30 2003 1 52 PM ...

Page 161: ...CAN HAPPEN You could be poisoned You could be HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes a...

Page 162: ...ealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU00876 Fuse replacement 1 The main fuse case and the fuse box are located under the seat 2 If a fuse is blown turn off the main switch and install a new fuse of the specified amperage Then turn on the switches If the fuse...

Page 163: ...e 3 Auxiliary DC jack fuse 4 Four wheel drive fuse 5 Signaling system fuse 6 Odometer fuse backup 7 Spare fuse 3 Specified fuses Main fuse 30 A Headlight fuse 15 A Ignition fuse 10 A Auxiliary DC jack fuse 10 A U5ND11 book Page 50 Wednesday April 30 2003 1 52 PM ...

Page 164: ... bulb holder cover at the rear of the headlight by pulling it off 1 Headlight bulb holder cover WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse U5ND11 book Page 51 Wednesday April 30...

Page 165: ... the bulb holder push it in and then turn it clock wise until it stops WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it U5ND11 book Page 52 Wednesday April 30 2003 1 52 ...

Page 166: ...e the transparency of the glass the luminos ity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb 5 Install the bulb holder by turning it clock wise 6 Install the bulb holder cover at the rear of the headlight U5ND11 book Page 53 Wednesday April 30 2003 1 52 PM ...

Page 167: ... adjustment _ To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b EBU01105 Tail brake light bulb replacement If the tail brake light bulb burns out have a Yamaha dealer replace it U5ND11 book Page 54 Wednesday April 30 2003 1 52 PM ...

Page 168: ...ence and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se vere ...

Page 169: ... the electric starter to see if there is compression There is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap Check the fuel flow Turn...

Page 170: ...er the cap Al low any remaining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the coolant reservoir and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See NOTE Restart the engine If the engine overheats again ask ...

Page 171: ...to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash er...

Page 172: ...nt or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings U5ND11 b...

Page 173: ...blespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing in a humid or salt ai...

Page 174: ...ry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine U5ND11 book Page 4 Wednesday April 30 2003 1 52 PM ...

Page 175: ... 32 6 in Wheelbase 1 233 mm 48 5 in Ground clearance 245 mm 9 65 in Minimum turning radius 3 000 mm 118 1 in Basic weight With oil and full fuel tank 267 kg 589 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 421 cm3 Bore stroke 84 5 75 0 mm 3 33 29 5 in Compression ratio 10 1 U5ND11 book Page 1 Wednesday April 30 2003 1 52 PM ...

Page 176: ... 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher U5ND11 book Page 2 Wednesday April 30 2003 1 52 PM ...

Page 177: ...23 L 0 2 Imp qt 0 24 US qt Radiator capacity including all routes 1 3 L 1 1 Imp qt 1 4 US qt Air filter Wet type element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 15 L 3 3 lmp gal 3 96 US gal Fuel reserve amount 4 5 L 0 99 lmp gal 1 19 US gal Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Model YFM450FA U5ND11 book Page 3 Wednesday April 30 2003 1 52 PM ...

Page 178: ...ary reduction system Spur gear Secondary reduction ratio 39 24 24 18 33 9 7 944 Transmission type V belt automatic Operation Left hand operation Reverse gear 29 17 1 706 Sub transmission ratio low 45 16 2 813 high 38 23 1 652 Chassis Frame type Steel tube frame Caster angle 4 0 Trail 21 mm 0 83 in Tire Model YFM450FA U5ND11 book Page 4 Wednesday April 30 2003 1 52 PM ...

Page 179: ...ble wishbone Rear suspension Swingarm monocross Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 160 mm 6 3 in Rear wheel travel 180 mm 7 09 in Electrical Ignition system DC C D I Generator system A C magneto Battery type YTX20L BS Model YFM450FA U5ND11 book Page 5 Wednesday April 30 2003 1 52 PM ...

Page 180: ... temperature warning light LED Park indicator light LED High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Fuses Main fuse 30 A Headlight fuse 15 A Ignition fuse 10 A Auxiliary DC jack fuse 10 A Four wheel drive fuse 3 A Signaling system fuse 10 A Model YFM450FA U5ND11 book Page 6 Wednesday April 30 2003 1 52 PM ...

Page 181: ...se of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muff...

Page 182: ...is not acceptable proof of maintenance work ACL 02EACL 02E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 200 mi 320 km or 20 hours 750 mi 1 200 km or 75 hours 1 500 mi 2 400 km or 150 hours 3 000 mi 4 800 km or 300 hours 4 500 mi 7 200 km or 450 hours 6 000 mi 9 600 km or 600 hours 7 500 mi 12 000 km or 750 hours 9 000 mi 14 400 km or 900 hours 10 500 mi 16...

Page 183: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U5ND11 book Page 1 Wednesday April 30 2003 1 52 PM ...

Page 184: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U5ND11 book Page 2 Wednesday April 30 2003 1 52 PM ...

Page 185: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S U5ND11 book Page 1 Wednesday April 30 2003 1 52 PM ...

Page 186: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U5ND11 book Page 2 Wednesday April 30 2003 1 52 PM ...

Page 187: ...EBU00437 U5ND11 book Page 3 Wednesday April 30 2003 1 52 PM ...

Page 188: ...EBU00438 ...

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