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Yamaha KODIAK 700 YFM70KDXG, Owner'S Manual, Page: 10 / 180

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Yamaha KODIAK 700 YFM70KDXG Owner'S Manual Download Page 10

Instruments, lights and switches ................ 5-7

OPERATION ................................................... 6-1

Starting the engine ...................................... 6-1
Operating the drive select lever and 

driving in reverse....................................... 6-2

Engine break-in ........................................... 6-4
Parking ........................................................ 6-5
Parking on a slope ...................................... 6-5
Accessories and loading ............................. 6-6

RIDING YOUR ATV ........................................ 7-1

GETTING TO KNOW YOUR ATV ................ 7-2
RIDE WITH CARE AND GOOD 

JUDGMENT .............................................. 7-2

BE CAREFUL WHERE YOU RIDE............... 7-9
TURNING YOUR ATV................................ 7-12
CLIMBING UPHILL ................................... 7-13
RIDING DOWNHILL .................................. 7-16
CROSSING A SLOPE................................ 7-17
CROSSING THROUGH SHALLOW 

WATER.................................................... 7-18

RIDING OVER ROUGH TERRAIN ............. 7-20
SLIDING AND SKIDDING.......................... 7-21
WHAT TO DO IF... ..................................... 7-22
WHAT TO DO... ......................................... 7-22

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

Owner’s manual and tool kit....................... 8-2
Periodic maintenance chart for the 

emission control system........................... 8-3

General maintenance and lubrication 

chart.......................................................... 8-5

Removing and installing panels................ 8-10
Checking the spark plug........................... 8-18
Engine oil and oil filter cartridge ............... 8-21
Final gear oil ............................................. 8-25
Differential gear oil.................................... 8-28
Coolant ..................................................... 8-30
Cleaning the air filter element ................... 8-37
Cleaning the spark arrester ...................... 8-40
V-belt case drain plug............................... 8-41
Adjusting the throttle lever free play......... 8-42
Valve clearance......................................... 8-42
Adjusting the drive select lever safety 

system cable .......................................... 8-43

Brakes....................................................... 8-43
Checking the front brake pads and rear 

brake friction plates ................................ 8-43

Checking the brake fluid level .................. 8-44
Changing the brake fluid .......................... 8-45
Checking the front brake lever free play... 8-45

UB1660E0.book  Page 2  Thursday, February 26, 2015  4:01 PM

Summary of Contents for KODIAK 700 YFM70KDXG

Page 1: ... PROPRIÉTAIRE MANUAL DEL PROPIETARIO B16 F8199 60 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad ...

Page 2: ...DIC183 Original instructions Notice originale Manual original PRINTED IN USA 2015 03 1 9 1 CR E F S ...

Page 3: ...ns important safety information WARNING OWNER S MANUAL YFM70KDXG YFM70KDHG YFM70KPXG YFM70KPHG YFM70KPSG This ATV should not be ridden by anyone under 16 years of age B16 F8199 60 E0 UB1660E0 book Page 1 Thursday February 26 2015 4 01 PM ...

Page 4: ...laan 101 1119 NC Schiphol Rijk The Netherlands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title and or numb...

Page 5: ...e 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 or specifications Authorized Represent...

Page 6: ... understanding of the features and operation of this ATV This manual includes important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read thi...

Page 7: ...fety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key informa...

Page 8: ... check your local riding laws and regulations before operating this ATV EBU17411 YFM70KDXG YFM70KDHG YFM70KPXG YFM70KPHG YFM70KPSG OWNER S MANUAL 2015 by Yamaha Motor Co Ltd 1st edition February 2015 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 UB1660E0 book Page 1 Thursday February 26 2015 4 0...

Page 9: ...ttle lever 4 16 Speed limiter 4 16 Front brake lever 4 17 Brake pedal and rear brake lever 4 17 Drive select lever 4 18 Fuel tank cap 4 18 Fuel 4 19 Seat 4 20 Storage compartment 4 21 Front carrier 4 23 Rear carrier 4 23 Adjusting the front and rear shock absorber assemblies YFM70KPXG YFM70KPHG YFM70KPSG 4 23 Trailer hitch YFM70KPXG YFM70KPHG YFM70KPSG 4 24 Auxiliary DC jack 4 25 PRE OPERATION CHE...

Page 10: ...ENT 8 1 Owner s manual and tool kit 8 2 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing panels 8 10 Checking the spark plug 8 18 Engine oil and oil filter cartridge 8 21 Final gear oil 8 25 Differential gear oil 8 28 Coolant 8 30 Cleaning the air filter element 8 37 Cleaning the spark arrester 8 40 V belt case dra...

Page 11: ... bushes 8 52 Lubricating the rear knuckle pivots 8 52 Lubricating the steering shaft 8 53 Battery 8 54 Replacing a fuse 8 57 Replacing a headlight bulb 8 59 Adjusting a headlight beam 8 62 Replacing the tail brake light bulb 8 63 Removing a wheel 8 64 Installing a wheel 8 65 Troubleshooting 8 66 Troubleshooting charts 8 67 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSU...

Page 12: ...l 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 UB1660E0 book Page 1 Thursday February 26 2015 4 01 PM ...

Page 13: ...1 2 1 For Europe 1 2 3 4 5 10 8 9 7 6 UB1660E0 book Page 2 Thursday February 26 2015 4 01 PM ...

Page 14: ...kgf 33 lbf 37S F817S 00 B16 F817R 10 90 kg 198 lbs 35 0 kPa 0 35 kgf cm 5 0 psi 30 0 kPa 0 30 kgf cm 4 4 psi 1HP F816M M0 YAMAHA B16 F817R 00 50 kg 110 lbs 1P0 F816P 20 YAMAHA 1 2 3 4 5 UB1660E0 book Page 3 Thursday February 26 2015 4 01 PM ...

Page 15: ...OTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWBD 36 0 kW 307 kg 2015 2SM F155A 00 YAMAHA 1HP F811R 00 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWBD 36 0 kW 312 kg 2015 B32 F155A 00 6 YFM70KDXG YFM70KDHG 6 YFM70KPXG YFM70KPHG 6 YFM70KPSG 7 8 UB1660E0 book Page 4 Thursday February 26 2015 4 01 PM ...

Page 16: ...1 5 1 1P0 F816R 00 YAMAHA B16 F816N 01 4 kg 9 lb 9 10 UB1660E0 book Page 5 Thursday February 26 2015 4 01 PM ...

Page 17: ...om 12 years old Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 16 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 li...

Page 18: ...ss of control Adjust the tire pressure Improper tire pressure 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 relat...

Page 19: ...1 8 1 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN kW kg 1 2 3 4 1 2 3 4 Year of construction Model Name Max Power Mass In Running Order UB1660E0 book Page 8 Thursday February 26 2015 4 01 PM ...

Page 20: ...1 9 1 For Oceania 3 5 4 9 6 7 8 1 2 UB1660E0 book Page 9 Thursday February 26 2015 4 01 PM ...

Page 21: ...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 UB1660E0 book Page 10 Thursday February 26 2015 4 01 PM ...

Page 22: ...gh terrain Maximum Vehicle Load 240 kg 530 lbs Includes weight of operator cargo and accessories and if applicable trailer tongue weight WARNING B16 F816M 00 YAMAHA IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold LOADING TRAILER TOWING WARNING NEVER operate this ATV if you are under age...

Page 23: ...at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANU...

Page 24: ... 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 as...

Page 25: ...g 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 Shift y...

Page 26: ...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 are ...

Page 27: ...ry 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 your ...

Page 28: ...he 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 provided un der Loading when mounting accessories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before u...

Page 29: ...deadly levels of carbon monoxide can linger for hours or days in en closed or poorly ventilated areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run e...

Page 30: ...ge 9 Coolant reservoir 5 1 2 3 4 7 8 6 9 1 Rear shock absorber assembly spring preload adjusting ring YFM70KPXG YFM70KPHG YFM70KPSG 2 Fuel tank cap 3 Owner s tool kit 4 Storage compartment 5 Spark plug 6 Front shock absorber assembly spring preload adjusting ring YFM70KPXG YFM70KPHG YFM70KPSG 7 Brake pedal 8 V belt case drain plug 5 1 6 2 3 4 7 8 UB1660E0 book Page 1 Thursday February 26 2015 4 01...

Page 31: ...r 8 Throttle lever 9 Auxiliary DC jack 10 Main switch 1 2 3 4 5 6 7 8 9 10 1 Drive select lever 2 Rear brake lever 3 Handlebar switches 4 Drive lever 2WD 4WD YFM70KPXG YFM70KPHG 5 Multi function display 6 Front brake fluid reservoir 7 On Command four wheel drive differential gear lock switch YFM70KPSG 8 Front brake lever 9 Throttle lever 10 Auxiliary DC jack 11 Main switch 1 2 3 4 5 6 7 8 9 1011 U...

Page 32: ...3 3 3 TIP The ATV you have purchased may differ slightly from the figures shown in this manual UB1660E0 book Page 3 Thursday February 26 2015 4 01 PM ...

Page 33: ... follows on All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed off All electrical systems are off The key can be re moved 1 Main switch 1 UB1660E0 book Page 1 Thursday February 26 2015 4 01 PM ...

Page 34: ...ght 1 2 3 4 5 6 7 1 On Command differential gear lock indicator light DIFF LOCK YFM70KPSG 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 P 7 Four wheel drive indicator 8 On Command differential gear lock indicator YFM70KPSG 9 Engine trouble warning light 10 Coolant temperature warning light 11 Electric Pow...

Page 35: ...t temperature warning light This warning light comes on when the engine overheats When this occurs during operation stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes The electrical circuit of the warning light can be checked by turning the key to on The warning light should come on for a few seconds and then go off If the warning light does not come on i...

Page 36: ...ctly When this occurs have a Yamaha dealer check the self diagnosis system YFM70KPXG YFM70KPHG YFM70KPSG See page 4 8 for an explanation of the self diagnosis device The electrical circuit of the warning light can be checked by turning the key to on The warning 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 ...

Page 37: ...g Four wheel drive indicator YFM70KPXG YFM70KPHG YFM70KPSG This indicator comes on when the drive lever or the On Command four wheel drive switch is set to the 4WD position TIP Due to the synchronizing mechanism in the differ ential gear case the indicator may not come on until the ATV starts moving On Command differential gear lock indicator and indicator light DIFF LOCK YFM70KPSG This indicator ...

Page 38: ...eter and tripmeter modes Pushing the SELECT button switches the dis play between the odometer mode ODO and the tripmeter modes TRIP A and TRIP B in the fol lowing order ODO TRIP A TRIP B ODO To reset a tripmeter select it by pushing the SE LECT button and then push the RESET button for at least three seconds The tripmeters can be used to estimate the distance that can be traveled with a full tank ...

Page 39: ...nd the minute digits will start flashing 5 Push the RESET button to set the minutes 6 Push the SELECT button and then release it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear from F full towards E empty as the fuel level decreases When the E segment disappears and the fuel level warning indicator flashes ...

Page 40: ...n any of those circuits the multi function display will indicate an error code If the multi function display indicates an error code note the code number and then have a Yamaha dealer check the vehicle 1 Fuel level warning indicator 2 Fuel meter 3 E segment 1 2 3 1 Error code display 1 UB1660E0 book Page 8 Thursday February 26 2015 4 01 PM ...

Page 41: ...tch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situa tion The engine will not start or run when this switch is set to 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 ...

Page 42: ... oth erwise the battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 54 EBU18171 Horn switch Press the switch to sound the horn EBU18192 Override switch OVERRIDE YFM70KPSG Top speed is normally limited when operating in differential gear lock If conditions require more engine power when riding forwar...

Page 43: ...turn for the speed you are trav eling EBU26608 On Command four wheel drive switch 2WD 4WD YFM70KPSG 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...

Page 44: ... The ATV handles differently in four wheel drive than in differential gear lock in some circum stances Changing from four wheel drive to differential gear lock or vice versa while mov ing may cause the ATV to handle differently un expectedly This could distract the operator and increase the risk of losing control and causing an accident WARNING EWB00141 Always ride at a slow speed when the ATV is ...

Page 45: ...ied to the rear and front wheels LOCK four wheel drive with the differential gear locked Power is supplied to the rear and front wheels and the differential gear is locked Unlike in four wheel drive all wheels turn at the same speed To lock the differential gear in four wheel drive make sure the On Command four wheel drive switch is pushed in to the 4WD position 1 On Command four wheel drive switc...

Page 46: ...he switch to the 4WD position TIP When the switch is set to LOCK or 4WD the differential gear lock indicator and indicator light will flash until the differential gear is completely locked or unlocked When the indicator and indicator light are flash ing turning the handlebar back and forth will help the differential gear lock to engage or dis engage 1 Differential gear lock lever 2 On Command four...

Page 47: ...eel 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 handle differently This could distract the oper ator and increase the risk of losing control and of causing an accident This vehicle is equipped with a lever to change from two wheel drive to four wheel drive and vice versa Select t...

Page 48: ...t is operating smoothly Make sure it returns to the idle position as soon as the lever is released EBU18324 Speed limiter Your ATV is equipped with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum 1 Loosen the locknut 2 To increase the maximum engine power available and the maximum speed of the ATV turn the ad...

Page 49: ...eration You could lose control resulting in an accident EWB00242 3 Tighten the locknut EBU18392 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 EBU18443 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar ...

Page 50: ...d park positions See the Operating the drive select lever and driving in reverse section on page 6 2 for the drive select lever operation EBU18721 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise 1 Brake pedal 1 Rear brake lever 1 1 1 Drive select lever 1 UB1660E0 book Page 18 Thursday February 26 2015 4 01 PM ...

Page 51: ...moking 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 sun can caus...

Page 52: ...71 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 Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of 91 or higher 95 or higher for Europe If knocking or pinging occurs use a gasoline of a different brand Use of unleaded fu...

Page 53: ...2320 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 Seat 1 1 Projection 2 Seat holder 1 1 2 2 UB1660E0 book Page 21 Thursday Febru...

Page 54: ... exceed the load limit of 4 0 kg 9 lb for the storage compartment Do not exceed 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 1 Storage compartment lid 1 Storage compartment 1 1 UB1660E0 book Page 22 Thursda...

Page 55: ...ight and the riding conditions WARNING EWB00401 Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac cident Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in d...

Page 56: ...2 Trailer hitch YFM70KPXG YFM70KPHG YFM70KPSG This ATV is equipped with a 5 cm 2 in trailer hitch receiver 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 UB1660E0 book Page 24 Thursday February 26 2015 4 01 PM ...

Page 57: ...he engine is running and the light switch is set to OFF 1 Set the light switch to OFF 2 Turn the accessory off 3 Start the engine See page 6 1 4 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 5 Turn the accessory on 6 When the auxiliary DC jack is not being used cover it with the cap 1 Trailer hitch receiver 1 1 Auxiliary DC jack cap 2 Auxiliary DC jack Maxi...

Page 58: ...to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine start ing may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged UB1660E0 book Page 26 Thursday February 26 2015 4 01 PM ...

Page 59: ... 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 4 19 5 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 5 3 8 21 Final gear oil Check ATV for oil ...

Page 60: ...free play and adjust if necessary 5 4 8 42 Control cables Make sure that operation is smooth Lubricate if necessary 8 49 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 51 Brake levers Make s...

Page 61: ...30 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 is incorrect adjust it ...

Page 62: ... operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19815 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use the low pressure tire gauge to check and ad just tire pressures when the tires are cold Tire pressures mu...

Page 63: ...the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended tire pressure Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum tire pressure Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi 1 Low pressure tire gauge UB1660E0 book Page 5...

Page 64: ...termarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate 1 Tire wear limit Front Manufacturer model CHENG SHIN C828 AUS NZL MAXXIS MU19 EUR FRA GBR Size AT25 x 8 12 Type Tubeless Rear Manufacturer model CHE...

Page 65: ...re 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 UB1660E0 book Page 7 Thursday February 26 2015 4 01 PM ...

Page 66: ...the engine is started The following warning lights should come on for a few seconds then go off Coolant temperature warning light Engine trouble warning light Fuel level warning light for equipped mod els NOTICE ECB00825 If a warning light does not go off see page 4 2 for the corresponding warning light circuit check To avoid possible damage do not oper ate the ATV if a warning light stays on 2 Ap...

Page 67: ...ttempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt NOTICE ECB00164 For maximum engine life never accelerate hard when the engine is cold EBU20442 Operating the drive select lever and driving in reverse NOTICE ECB00171 Before shifting stop the ATV otherwise the transmission may be damaged Shifting Neutral to Hi...

Page 68: ...le 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 The drive select lever cannot be shifted into or from reverse or park without applying 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 ra...

Page 69: ... in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various par...

Page 70: ...engine and shift the drive select lever into the park position EBU29901 Parking on a slope WARNING EWB00861 Avoid parking on hills or other inclines Parking on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident If you must park on an incline place the ATV transversely across the incline stop the engine shift the drive select lever to the park po...

Page 71: ...ftermarket products similar in design and quality to genuine Yamaha Accesso ries recognize that some aftermarket accessories or modifications are not suitable because of po tential safety hazards to you or others Installing aftermarket products or having other modifica tions performed to your ATV that change any of the vehicle s design or operation characteristics can put you and others at greater...

Page 72: ... can change the stability and han dling of an ATV You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable Do not exceed the maximum tongue weight You can measure tongue weight with a bath room scale Put the tongue of the loaded trailer on the scale with the tongue a...

Page 73: ...cident Make sure the load does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier ATV takes longer to stop Av...

Page 74: ...7 1 7 EBU21142 RIDING YOUR ATV UB1660E0 book Page 1 Thursday February 26 2015 4 01 PM ...

Page 75: ...n pages 2 1 2 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 of ...

Page 76: ... 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 control ...

Page 77: ...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 with...

Page 78: ...h time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 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 Fo...

Page 79: ...entered 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 ta...

Page 80: ...our 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 and t...

Page 81: ... 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 par...

Page 82: ...ces 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 UB1660E0 book ...

Page 83: ...y 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 con...

Page 84: ...ag 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 UB1660E0 book Page 11 Thursda...

Page 85: ...lease 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 proced...

Page 86: ...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 while ...

Page 87: ...ddenly 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 a s...

Page 88: ...d 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 cause you...

Page 89: ... 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 cause loss of traction...

Page 90: ...er 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 Impr...

Page 91: ...ay 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 CROS...

Page 92: ...de 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 th...

Page 93: ... such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to an upset or 1 Air filter case check hose 1 Storage compartment drain plug 1 1 1 V belt case drain plug 1 UB1660E0 book Page 20 Thursday Feb...

Page 94: ...lowly and be very cautious in order to re duce the chance of skidding or sliding out of control Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help I...

Page 95: ...osition your weight over the front wheels for better control See page 7 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 7 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 recommen...

Page 96: ...u discover that the ATV is going to tip over dismount on the uphill side See page 7 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 See ...

Page 97: ... 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 2 6 for more information about carbon monoxide WARNING EWB02691 Bra...

Page 98: ...d in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain 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...

Page 99: ...tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if necessary...

Page 100: ...d 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 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 UB1660E0 book Page 4 Thursday February 26 2015 4 01 PM ...

Page 101: ...ata and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 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 corre...

Page 102: ...ear 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 grease N...

Page 103: ...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 Which...

Page 104: ...d adjust or replace if neces sary 25 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 26 Front and rear brake switches Check operation and correct if necessary 27 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6...

Page 105: ... replace the internal components of the brake master cylinder and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged UB1660E0 book Page 9 Thursday February 26 2015 4 01 PM ...

Page 106: ...nce 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 UB1660E0 book Page 10 Thursday February 26 2015 4 01 PM ...

Page 107: ...e 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 UB1660E0 book Page 11 Thursday February 26 2015 4 01 PM ...

Page 108: ...d 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 UB1660E0 book Page 12 Thursday February 26 2015 4 01 PM ...

Page 109: ...1 Remove the seat See page 4 20 2 Remove panel A 3 Remove the hoses from panel C 4 Remove the quick fasteners and bolts Tightening torques Carrier bolt upper 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt lower 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Hose 1 1 UB1660E0 book Page 13 Thursday February 26 2015 4 01 PM ...

Page 110: ...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 UB1660E0 book Page 14 Thursday February 26 2015 4 01 PM ...

Page 111: ...rly 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 UB1660E0 book Page 15 Thursday February 26 2015 4 01 PM ...

Page 112: ...n 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 UB1660E0 book Page 16 Thursday February 26 2015 4 01 PM ...

Page 113: ... 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 UB1660E0 book Page 17 Thursday February 26 2015 4 01 PM ...

Page 114: ...nce and lubri cation chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove panels A and C See page 8 10 2 Remove the storage compartment by remov ing the bolt 3 Remove the spark plug cap Tightening torques Panel bolt 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard nut 4 0 Nm 0 40 m kgf 2 9 ft lbf 1 Storage compartment 2 Bolt 1 Spark plug ...

Page 115: ...ug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the vehicle 2 Check 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 1 Sp...

Page 116: ...ailable when installing the spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible 3 Install the spark plug cap 4 Install the storage compartment as shown and then install the bolt 5 Install the panels 1 Spark plug gap Spark plug gap 0 8 0 9 mm 0 031 0 035 in Tightening torque Spark ...

Page 117: ...l 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least 10 minutes until the oil set tles for an accurate reading 3 Remove the access cover by turning it coun terclockwise 4 Remove the engine oil dipstick and then wipe it off with a clean rag 1 Ac...

Page 118: ... 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 To change the engine oil with or without oil fil ter cartridge replacement 1 Place the ATV on a level surface 2 Remove the access cover by turning it coun terclockwise 3 Place an oil pan under the engine to collect the used oil 4 Remove the dipstick and t...

Page 119: ...filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer 7 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge 1 Engine oil drain bolt 2 Gasket 1 2 1 Oil filter cartridge 2 Oil filter wrench 1 2 UB1660E0 book Page 23 Thursday February 26 2015 4 01 PM ...

Page 120: ...que with a torque wrench 9 Install panel F 10 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 15 Nm 1 5 m kgf 11 ft lbf Tightening torque Engine oil drain bolt 22 Nm 2 2 m kgf 16 ft lbf 1 UB1660E0 book Page 24 Thursday February 26 2015 4 01 PM ...

Page 121: ...oil leakage If oil is leaking immediately turn the engine off and check for the cause 13 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 14 Install the access cover by turning it clock wise EBU27307 Final gear oil The final gear case must be checked for oil leak age before each ride If any leakage is found have a Yamaha dealer check and repair...

Page 122: ... raise it to the correct level 4 Check the gaskets for damage and replace them if necessary 5 Install the oil level check bolt the oil filler bolt and their gasket and then tighten the bolts to the specified torques 1 Final gear oil 2 Gasket 3 Final gear oil level check bolt 4 Correct oil level 1 2 4 3 1 Final gear oil filler bolt 2 Gasket Tightening torques Final gear oil level check bolt 10 Nm 1...

Page 123: ... bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended final gear oil to the brim of the check hole as shown NOTICE Be sure no foreign material en ters the final gear case ECB00422 1 Final gear oil drain bolt 2 Gasket 1 2 Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil 2 Gasket 3 Final gear oil level check bol...

Page 124: ...t the in tervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface 2 Remove the differential gear oil filler bolt and its gasket and then check the oil level in the differential gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of...

Page 125: ...he drain bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended differential gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material en ters the differential gear case ECB00412 Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Differential gear oil drain bolt 2 Gasket 1 2 Tightening torque Di...

Page 126: ...rvals specified in the periodic maintenance and lubrication chart 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 differential gear oil See ...

Page 127: ... 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 the c...

Page 128: ...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 8 10 3 Remove the footboard by removing the bolts and nuts 4 Place a container under the engine and then 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 Footboard 2 Bolt and nut 3 B...

Page 129: ... reservoir cap 7 Disconnect the coolant reservoir hose on the coolant reservoir side and then drain the coolant from the coolant reservoir 1 Coolant drain bolt 2 Gasket 1 Trough 1 2 1 1 Radiator cap UB1660E0 book Page 33 Thursday February 26 2015 4 01 PM ...

Page 130: ...ailable soft water may be used for refilling Do not use hard water or salt water since they are harmful to the engine ECB00992 13 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 hole 1 Coolant reservoir hose Tightening torque Coolant drain bolt 8 Nm 0 8 m kgf 5 8 ft lbf Antifreeze water mixture ratio 1 1 Recommended antifreeze Hi...

Page 131: ...ns to flow out of the bolt hole tighten the cylinder head air bleed bolt to the specified torque 18 Start the engine and let it idle for ten minutes 19 Rev the engine five times 20 Pour additional coolant into the radiator until it is full 1 Water pump air bleed bolt Tightening torque Water pump air bleed bolt 8 Nm 0 8 m kgf 5 8 ft lbf 1 1 Cylinder head air bleed bolt Tightening torque Cylinder he...

Page 132: ...cap 22 Start the engine and then check for coolant leakage TIP If any leakage is found have a Yamaha dealer check the cooling system 23 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 Footboard bolt B 3 1 2 1 UB1660E0 book Page 36 Thursday February 26 2015 4 ...

Page 133: ... unusually 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 Place the ATV on a level surface Tightening torques Footboard nut 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard bolt A 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard bolt B 8 Nm 0 8 m kgf 5 8 ft lbf 4 1 2 3 1 Air...

Page 134: ...lders 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 UB1660E0 book Page 38 Thursday February 26 2015 4 01 PM ...

Page 135: ...nd replace it if damaged 9 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...

Page 136: ...ed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the throttle body and the rub ber joint manifold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine EBU28904 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 R...

Page 137: ...ng possibly leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components 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 wate...

Page 138: ... increase the throttle lever free play turn the throttle lever free play adjusting bolt in di rection a To decrease the throttle lever free play turn the adjusting bolt in direction b 4 Tighten the locknut 5 Slide the rubber cover to its original position EBU24061 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from oc...

Page 139: ...ust ed brakes could lead to a loss in braking ability and an accident EBU28414 Checking the front brake pads and rear brake friction plates The front brake pads and the rear brake friction plates must be checked for wear at the intervals specified in the periodic maintenance and lubrica tion chart TIP This ATV is equipped with a wet multiple disc type rear brake which is located inside of the fina...

Page 140: ...ication chart EBU29843 Checking the brake fluid level Before riding check that the brake fluid is above the minimum level mark Check the brake fluid lev el with the top of the reservoir level Replenish the brake fluid if necessary WARNING EWB02721 Improper maintenance can result in loss of braking ability Observe these precautions 1 Wear indicator groove 1 Minimum level mark Specified brake fluid ...

Page 141: ...evel may indicate worn brake pads and or brake system leakage therefore be sure to check the brake pads for wear and the brake system for leakage If the brake fluid level goes down sud denly have a Yamaha dealer check the cause be fore further riding EBU24283 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrication ...

Page 142: ...riodic maintenance and lubrication chart Adjusting the brake lever free play The brake lever free play should measure 6 0 7 0 mm 0 24 0 28 in If the free play is incorrect ad just it as follows 1 Loosen the locknut at the brake lever 1 No brake lever free play 1 Brake lever free play 1 Locknut 2 Brake lever free play adjusting bolt 1 a b 1 2 UB1660E0 book Page 46 Thursday February 26 2015 4 01 PM ...

Page 143: ...ever free play turn the brake lever free play adjusting nut in direction a To decrease the brake lever free play turn the adjusting nut in direction b 7 Tighten the brake cable adjuster locknut 8 Slide the rubber cover to its original position 9 Tighten the locknut at the brake lever Adjusting the brake pedal free play The brake pedal free play should measure 12 0 17 0 mm 0 47 0 67 in If the free ...

Page 144: ...t 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 UB1660E0 book Page 48 Thursday February 26 2015 4...

Page 145: ...justing 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 Rear a...

Page 146: ...n 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 lubricant...

Page 147: ...ivot remove panel G See page 8 10 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 UB1660E0 book Page 51 Thur...

Page 148: ...a Yamaha dealer replace the stabilizer bush es if necessary EBU25053 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun Recommended lubricant Lithium soap based grease UB1660E0 book Page 52 Thursday February 26 2015 4 01 PM ...

Page 149: ...the intervals specified in the pe riodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun YFM70KDXG YFM70KDHG YFM70KPXG YFM70KPHG YFM70KPSG 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 UB1660E0 book Page 53 Thursday February 26 2015 4 01 PM ...

Page 150: ... EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ignition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH...

Page 151: ...B01002 5 Pull the battery out of its compartment To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional elec trical accessories 1 Carrier bolt under the fenders 2 Carrier bolt lower 1 2 2 1 1 Battery holding plate 2 Nut 3 Negative battery lead...

Page 152: ...y charged Storing a discharged battery can cause permanent bat tery damage To install the battery TIP Be sure the battery is fully charged 1 Place the battery in its compartment 2 Connect the positive battery lead first then connect the negative battery lead by installing their bolt NOTICE When installing the bat tery the main switch must be off and the positive lead must be connected before the n...

Page 153: ...3 4 m kgf 25 ft lbf Carrier bolt lower 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Fuse box 2 Main fuse 3 EPS fuse for EPS model 4 Fuel injection system spare fuse 5 Fuel injection system fuse 2 3 4 5 1 UB1660E0 book Page 57 Thursday February 26 2015 4 01 PM ...

Page 154: ... and then install a new fuse of the specified amperage WARNING Always use a fuse of the spec ified rating and never use a substitute ob ject in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical system which could lead to a fire EWB02173 1 Headlight fuse 2 Signaling system fuse 3 Radiator fan motor fuse 4 Ignition fuse 5 Four wheel drive motor fuse ...

Page 155: ...of the headlight by pulling it off 2 Remove the headlight bulb holder cover by pulling it off Specified fuses Main fuse 40 0 A Headlight fuse 10 0 A YFM70KDHG YFM70KDXG 15 0 A YFM70KPHG YFM70KPSG YFM70KPXG Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A YFM70KPSG Signaling system fuse 10 0 A Auxiliary DC jack fuse 10 0 A Radiator fan motor fuse 20 0 A Fuel injection system fuse 15 0 A EPS ...

Page 156: ...oth erwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the head light bulb using a cloth moistened with al cohol or thinner ECB00652 6 Install the bulb holder by pushing it in and turning it clockwise 1 Headlight bulb holder cover 1 Headlight bulb holder 1 1 1 Do not touch the glass part of ...

Page 157: ...eam if necessary Center headlight bulb YFM70KPXG YFM70KPHG YFM70KPSG 1 Remove the headlight cover by removing the quick fasteners 2 Remove the headlight bulb holder cover by pulling it off 3 Remove the headlight bulb holder by pushing it in and turning it counterclockwise 1 Headlight cover 2 Quick fastener 1 2 2 1 Headlight bulb holder cover 1 Headlight bulb holder 1 1 UB1660E0 book Page 61 Thursd...

Page 158: ... cohol or thinner ECB00652 6 Install the bulb holder by pushing it in and turning it clockwise 7 Install the bulb holder cover NOTICE Make sure the headlight bulb holder cover is se curely fitted over the bulb holder and seat ed properly ECB00672 8 Install the headlight cover as shown and then install the quick fasteners 9 Adjust the headlight beam if necessary EBU25553 Adjusting a headlight beam ...

Page 159: ...PXG YFM70KPHG YFM70KPSG EBU25614 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the tail brake light bulb holder to gether with the bulb by turning it counter clockwise 1 Headlight beam adjusting screw b a 1 1 Headlight beam adjusting screw b a 1 UB1660E0 book Page 63 Thursday February 26 2015 4 01 PM ...

Page 160: ...he bulb holder together with the bulb by turning it clockwise EBU25652 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel 1 Tail brake light bulb holder 1 Tail brake light bulb 1 1 1 Wheel nut 1 1 UB1660E0 book Page 64 Thursday February 26 2015 4 01 PM ...

Page 161: ...el Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side towards the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf 1 UB1660E0 book Page 65 Thursday February 26 2015 4 01 PM ...

Page 162: ... repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02281 Do not smoke when checking the fuel system Fuel can ignite or ex...

Page 163: ...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 quick...

Page 164: ...an be temporarily used instead provided that it is changed to the recommended coolant as soon as possible 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 the engine overheats aga...

Page 165: ... 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 warm ...

Page 166: ... 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 starter This will coat the cylinder wall with oil e Remove the spark plug cap fro...

Page 167: ...t Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more infor mation on storing the battery see page 8 54 TIP Make any necessary repairs before storing the ATV UB1660E0 book Page 3 Thursday February 26 2015 4 01 PM ...

Page 168: ...of measurement 3 0 dB A EUR FRA GBR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s EUR FRA GBR Uncertainty of measurement 0 0 m s YFM70KPHG YFM70KPSG_EUR FRA GBR YFM70KPXG_EUR FRA GBR 0 1 m s YFM70KDHG YFM70KDXG_EUR FRA GBR Vibration on handle EN1032 ISO5008 Will not exceed 2 5 m s EUR FRA GBR Uncertainty of measurement 0 3 m s EUR FRA GBR Engine Engine type Liquid cooled 4 stroke DOHC C...

Page 169: ...ty Coolant reservoir up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator including all routes 1 76 L 1 86 US qt 1 55 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 18 0 L 4 75 US gal 3 96 Imp gal Fuel reserve amount 4 0 L 1 06 US gal 0 88 Imp gal Fuel injection Throttle body ID mark B161 00 Spark plug s Manuf...

Page 170: ... NZL MAXXIS MU19 EUR FRA GBR Rear tire Type Tubeless Size AT25 x 10 12 Manufacturer model CHENG SHIN C828 AUS NZL MAXXIS MU20 EUR FRA GBR Loading Maximum loading limit 240 0 kg 530 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum Front 32 0 kPa 0 320 kgf cm 4 6 p...

Page 171: ...uble wishbone Spring shock absorber type Coil spring oil damper Wheel travel 232 mm 9 1 in Electrical system Ignition system TCI Charging system AC magneto Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Headlight Bulb type Krypton bulb High mounted headlight bulb type Halogen bulb YFM70KPHG YFM70KPSG YFM70KPXG Bulb voltage wattage quantity Headlight 12 V 30 0 30 0 W 2 High mounted headlight...

Page 172: ...0KPHG YFM70KPSG YFM70KPXG Headlight fuse 10 0 A YFM70KDHG YFM70KDXG 15 0 A YFM70KPHG YFM70KPSG YFM70KPXG Signaling system fuse 10 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Four wheel drive motor fuse 10 0 A YFM70KPSG Radiator fan motor fuse 20 0 A EBU30402 For Europe only The figures quoted are emission levels and are not necessarily safe working levels Whilst there is a correlation b...

Page 173: ...6 10 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 UB1660E0 book Page 6 Thursday February 26 2015 4 01 PM ...

Page 174: ...LABEL INFORMATION EBU26031 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to iden tify your ATV EBU26051 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamah...

Page 175: ...11 2 11 1 Model label 1 UB1660E0 book Page 2 Thursday February 26 2015 4 01 PM ...

Page 176: ...erential gear lock indicator YFM70KPSG 4 5 Differential gear oil 5 3 8 28 Drive lever YFM70KDXG YFM70KDHG YFM70KPXG YFM70KPHG 4 15 Drive select lever 4 18 Drive select lever and driving in reverse 6 2 Drive select lever safety system cable adjusting 8 43 E Engine break in 6 4 Engine oil 5 3 Engine oil and oil filter cartridge 8 21 Engine stop switch 4 9 Engine trouble warning light 4 4 EPS warning...

Page 177: ...0 Park indicator light 4 3 Parking 6 5 Parking on a slope 6 5 Part locations 3 1 R Rear brake adjusting the lever pedal free play 8 46 Rear knuckle pivots lubricating 8 52 Reverse indicator light 4 3 Riding your ATV 7 1 S Safety information 2 1 Seat 4 20 Shock absorber assemblies adjusting the front and rear YFM70KPXG YFM70KPHG YFM70KPSG 4 23 Spark arrester cleaning 8 40 Spark plug checking 8 18 S...

Page 178: ...lve clearance 8 42 V belt case drain plug 8 41 Vehicle identification number 11 1 W Wheel hub bearings checking 8 51 Wheel installing 8 65 Wheel removing 8 64 UB1660E0 book Page 3 Thursday February 26 2015 4 01 PM ...

Page 179: ...UB1660E0 book Page 4 Thursday February 26 2015 4 01 PM ...

Page 180: ...PROVED 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 WA...

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