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Yamaha Kodiak YFM45FAV, Owner'S Manual

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Yamaha Kodiak YFM45FAV Owner'S Manual Download Page 46

4-24

1. Special wrench

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. 

EE.book  Page 24  Friday, May 6, 2005  8:59 AM

Summary of Contents for Kodiak YFM45FAV

Page 1: ...1D9 F8199 12 LIT 11626 19 57 READ THIS MANUAL CAREFULLY It contains important safety information This ATV should not be ridden by anyone under 16 years of age WARNING YFM45FAV OWNER S MANUAL ...

Page 2: ...EBU00776 ...

Page 3: ...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 YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS...

Page 4: ...t Symbol 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 clea...

Page 5: ...arrester laws and regu lations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU01067 YFM45FAV OWNER S MANUAL 2005 by Yamaha Motor Corporation U S A 1st edition June 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A...

Page 6: ...abel 3 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 1 2 3 4 Indicator and warning lights 4 2 Fuel gauge 4 4 Speedometer unit 4 5 Handlebar switches 4 7 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 17 Fuel tank cap 4 18 Fuel cock 4 18 Starter choke 4 20 Seat 4 20 Storage compartment 4 21 Front carrier 4 22 Re...

Page 7: ... 3 Warming up 6 3 Drive select lever operation and reverse driving 6 4 Engine break in 6 7 Parking 6 8 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 Ridin...

Page 8: ...retor adjustment 8 36 Idle speed adjustment 8 37 Valve clearance adjustment 8 38 Throttle lever adjustment 8 38 Select lever safety system cable adjustment 8 39 Front brake pad check 8 39 Rear brake pad check 8 40 Inspecting the brake fluid level 8 41 Brake fluid replacement 8 42 Front brake lever free play 8 43 Adjusting the rear brake lever and brake pedal 8 44 Adjusting the rear brake light swi...

Page 9: ...hooting 8 59 Troubleshooting charts 8 61 CLEANING AND STORAGE 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 EE book Page 4 Friday May 6 2005 8 59 AM ...

Page 10: ...1 1 EBU00464 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS EE book Page 1 Friday May 6 2005 8 59 AM ...

Page 11: ...comes difficult 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 EE book Page 2 Frida...

Page 12: ...ident Never 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 EE book Page 3 Friday May 6 2005 8 59 AM ...

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 5ND F1558 00 WARNING EE book Page 4 Friday May 6 2005 8 59 AM ...

Page 14: ...ng 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 ATV without adult supervision and never allow ...

Page 15: ...ce 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 Never operate on excessively rough slippery or loose terrain until you have learned and prac ticed t...

Page 16: ...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 possible Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stall ing u...

Page 17: ...ys be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper 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 prop...

Page 18: ...ources of ignition such as the pilot lights of water heaters and clothes dry ers 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 g...

Page 19: ...gine in 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 EE book Page 6 Friday May 6 2005 8 59 AM ...

Page 20: ... cock 11 Air filter case 12 Fuses 13 Tail brake light 14 Engine oil dipstick 15 Oil filter cartridge 16 Coolant reservoir 17 V belt cooling duct check hose 18 Rear brake lever 19 Left handlebar switches 20 Starter choke 21 Drive select lever 22 Speedometer unit 23 Main switch 24 Fuel tank cap 25 Auxiliary DC jack 26 Right handlebar switch 27 Throttle lever 28 Front brake lever NOTE The machine you...

Page 21: ...ordering 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 EE book Page 2 Friday Ma...

Page 22: ...The vehicle 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 EE book Page 3 Friday May 6 2005 8 59 AM ...

Page 23: ...eath EBU09420 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight 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 EE book Page 1 Friday May 6 2005 8 59 AM ...

Page 24: ...s 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 select lever is in the L positio...

Page 25: ...ive select lever is in the P park position EBU11312 Four wheel drive indicator This indicator comes on when the 2WD 4WD switch is set to the 4WD position The differential gear lock indicator DIFF LOCK in the four wheel drive indicator also comes on when the LOCK 4WD switch is set to the 4WD LOCK position NOTE _ Due to the synchronizing mechanism in the differential gear case the four wheel drive i...

Page 26: ...oaded 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 damage to the engine _ EBU00052 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank When the needle reaches the red line refill the tank at the first opportunity 1 Fuel gauge 2 Red line NOTE _ If the machine runs out of fuel move...

Page 27: ...utton The speedometer unit is equipped with the following a speedometer which shows the riding speed an odometer which shows the total dis tance traveled two tripmeters which show the distance traveled since they were last set to zero a clock an hour meter which shows the total time the key has been turned to ON EE book Page 5 Friday May 6 2005 8 59 AM ...

Page 28: ... el This information will enable you to plan future fuel stops NOTE _ Holding in the TRIP ODO button and then turning the key to ON switches the display between mph and km h _ Clock mode Pushing the button switches the display between the clock mode CLOCK and the hour meter mode HOUR in the fol lowing order CLOCK HOUR CLOCK To set the clock 1 Set the display to the clock mode 2 Push the button unt...

Page 29: ...lights with the engine turned off for more than thirty minutes 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 _ EBU12050 Engine stop switch Make sure 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 engin...

Page 30: ...ted when operating in 4WD LOCK If conditions require more en gine power when riding forward push and hold this switch to override the 4WD LOCK speed limiting function See pages 4 11 4 13 for a detailed explanation about the differential gear lock switch and its function Releasing the switch restores the speed limiting function While this switch is pushed the segments of the speedometer digits will...

Page 31: ...e 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 LOCK and allow ext...

Page 32: ... switch LOCK 4WD Select the appropriate drive according to ter rain and the conditions Two wheel drive 2WD Power is supplied to the rear wheels only Four wheel drive 4WD Power is supplied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels when the differen tial gear is locked DIFF LOCK Unlike the 4WD mode all whee...

Page 33: ...AL HAZARD Changing from 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 losi...

Page 34: ...it display To release the differential gear lock stop the ATV and set the switch to 4WD DIFF LOCK 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 You may lose control and have an accident if you cannot make a ...

Page 35: ...LOCK the maximum traveling speed is limited 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 pages 4 8 4 9 for a detailed explanation of this switch _ EBU00062 Throttle lever Once the engine is running movement of the throttle lever will increase the engine speed Regulate the speed of the ...

Page 36: ...ses the maximum speed of the ATV 1 Locknut 2 Adjusting screw a No more than 12 mm 0 47 in 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 before you start the engine If it does not work sm...

Page 37: ... on the pedal or pull the lever toward the handlebar to apply the rear brake 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...

Page 38: ...Drive select lever The drive select lever is used to shift your ma chine into the low high neutral reverse and park positions Refer to pages 6 4 6 6 for the drive select lever operation 1 Drive select lever EE book Page 16 Friday May 6 2005 8 59 AM ...

Page 39: ...e way out 1 Recoil starter WARNING POTENTIAL HAZARD 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 EE book Page 17 Friday May 6 2005 8 59 AM ...

Page 40: ... fuel will not flow Always turn the lever to this position when the engine is not running 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 t...

Page 41: ...4 19 1 Arrow mark pointing to OFF 1 Arrow mark pointing to ON 1 Arrow mark pointing to RES OFF Position ON Position RES Position EE book Page 19 Friday May 6 2005 8 59 AM ...

Page 42: ... 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 pages 6 1 6 3 1 Starter choke EBU05670 Seat To remove the seat pull the seat lock lever upward and pull up the seat at the rear 1 Seat 2 Seat lock lever EE book Page 20 Friday May 6 2005 8 59 AM ...

Page 43: ...See pages 4 20 4 21 for seat re moval and installation procedures When storing any documents in the storage compartment 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 ...

Page 44: ... 1 Storage compartment 1 Storage compartment check hose EBU00582 Front carrier EBU00583 Rear carrier Maximum load limit 40 kg 88 lb Maximum load limit 80 kg 176 lb EE book Page 22 Friday May 6 2005 8 59 AM ...

Page 45: ...ws 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 2 Position indicator NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ Standard position 2 1 Minimum soft 5 Maximum hard EE book Page 23 Friday May 6 2005 8 59 AM ...

Page 46: ... 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 EE book Page 24 Friday May 6 2005 8 59 AM ...

Page 47: ... the jack 4 When the auxiliary 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...

Page 48: ...4 26 1 Auxiliary DC jack EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death EE book Page 26 Friday May 6 2005 8 59 AM ...

Page 49: ...el Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 6 8 12 8 17 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 7 8 22 8 27 Final gear oil and differential gear oil Check for leakage 5 6 8 17 8 22 Throttle Check for proper throttle cable operation and free play 5 7 8 38 Wheels and tires Check tire pressure wear and dama...

Page 50: ...should be a firm feeling when the brakes are applied If not have a Yamaha dealer inspect the brake system Brake fluid level Check the brake fluid level Add fluid if neces sary See pages 8 41 8 42 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 HAZ...

Page 51: ...re they are working properly If the brakes do not provide proper braking per formance inspect the brake pads for wear See pages 8 39 8 40 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...

Page 52: ...en designed 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 0 L 3 30 Imp gal 3 96 US gal...

Page 53: ...NTIAL HAZARD 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 s...

Page 54: ...he 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 20 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 differential gear oil is at the specified...

Page 55: ... not get distilled water _ EBU01083 Throttle lever Check to see that the throttle lever operates correctly It must open smoothly and spring back to the idle position when released Have a Yamaha dealer repair as necessary for proper operation Coolant reservoir capacity up to the maximum level mark 0 25 L 0 22 Imp qt 0 26 US qt WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and ...

Page 56: ...aler 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 The tires listed below have been...

Page 57: ...ecified 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 carefu...

Page 58: ...e 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 Rear 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 EE book ...

Page 59: ...5 11 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 EE book Page 11 Friday May 6 2005 8 59 AM ...

Page 60: ...ng familiar with all controls WHAT CAN 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 ...

Page 61: ...neutral 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 warming up position 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...

Page 62: ...ion 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding 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 n...

Page 63: ...ged _ Shifting Neutral to High and High to Low 1 Bring the ATV to a complete stop and re turn the throttle lever to the closed posi tion 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 pletely shifted into position _ 1 Drive select lever 3 Open the throttle lever gradually EE book Page 4 Friday May 6 2005 8 59...

Page 64: ...al 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 electrical circuit Due to the synchronizing mechanism in the engine the light may not come on un til the ATV starts moving _ 4 Check behind f...

Page 65: ...ARD Improperly 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 EE book Page 6 Friday May 6 2005 8 59 AM ...

Page 66: ...n which 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 t...

Page 67: ...use full 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 EE book Page 8 Friday May 6 2005 8 59 AM ...

Page 68: ...AT CAN 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 the...

Page 69: ...hoose a 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 objec...

Page 70: ...icle 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 an acci dent Make sure the load does not interfere with controls or your abili...

Page 71: ...s Avoid 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 distrib...

Page 72: ...6 13 EBU15480 WARNING _ Indicates a potential hazard that could result in serious injury or death EE book Page 13 Friday May 6 2005 8 59 AM ...

Page 73: ...7 1 7 1 Riding Your ATV EE book Page 1 Friday May 6 2005 8 59 AM ...

Page 74: ... 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 activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual comp...

Page 75: ...re 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 creased if the operator does not know how to operate the ATV properly in dif ferent situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training cour...

Page 76: ...e recommenda 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 EE book Page 5 Friday May 6 2005 8 59 AM ...

Page 77: ...N HAPPEN 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 EE book Page 6 Friday May 6 2005 8 59 AM ...

Page 78: ... cident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event of an accident 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 b...

Page 79: ...AL HAZARD 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 EE book Page 8 Friday May 6 2005 8 59 AM ...

Page 80: ...n Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual 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 AVO...

Page 81: ...sting 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 pages 4 14 4 15 for details 1 Locknut 2 Adjusting screw 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 tr...

Page 82: ...ad 500 kgf 1 102 lbf Total weight of trailer and cargo Tongue weight 15 kgf 33 lbf Vertical weight on trailer hitch point 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 dis...

Page 83: ...oving even 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 opera...

Page 84: ...WARNING 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 EE book Page 13 Friday May 6 2005 8 59 AM ...

Page 85: ... 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 and used according to instructions If you have questions consult an autho rized ATV dealer EE book Page 14 Fri...

Page 86: ...s 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 operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the AT...

Page 87: ...rating 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 EE book Page 16 Friday May 6 2005 8 59 AM ...

Page 88: ...ARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways EE book Page 17 Friday May 6 2005 8 59 AM ...

Page 89: ...o 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 alert to changing terrain conditions when operating the ATV EE book Page 18 Friday...

Page 90: ...ction or 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 EE book Page 19 Friday May 6 2005 8 59 AM ...

Page 91: ... trespassing Do not ride on private property without getting permission WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be 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 EE book Page 20 Friday May 6 2005 8 59 A...

Page 92: ...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 of directional con trol Avoid higher speeds ...

Page 93: ...o 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 an even speed through the turn This maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control...

Page 94: ...ned this technique you should be able to perform it at higher speeds or in tighter curves Improper 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 le...

Page 95: ...s important 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 ...

Page 96: ...his 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 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 EE book Page 25 Fr...

Page 97: ...ING 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 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 possib...

Page 98: ...de of a 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 EE book Page 27 Friday May 6 2005 8 59 AM ...

Page 99: ...rake will brake all wheels When descending hills using either brake lever or the brake ped al will brake the wheels on the downhill side Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground The ATV could easily tip over backwards Apply both the front and rear brakes gradually or dis mount the ATV immediately on the uphill side W...

Page 100: ...stopped 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 EE book Page 29 Friday May 6 2005 8 59 AM ...

Page 101: ...ing may 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 cau...

Page 102: ...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 would cause the vehicle to lean sharply to one side Go straight down the hill where possible EE book Page 31 Friday May 6 ...

Page 103: ...p over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING 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 until yo...

Page 104: ...7 33 EE book Page 33 Friday May 6 2005 8 59 AM ...

Page 105: ... 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 Never operate this ATV in fast flowing water or in water deeper than that spec ified in your Owner s Manual Remember that wet brakes may have re duced stopping ability Test your brakes af...

Page 106: ... 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 _ 1 Air filter case check hose EE book Page 35 Friday...

Page 107: ...7 36 1 V belt cooling duct check hose left front side of ATV 1 Drive select lever box check hose 1 Storage compartment check hose 1 V belt case drain plug EE book Page 36 Friday May 6 2005 8 59 AM ...

Page 108: ...f control 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 ...

Page 109: ...front wheels 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 EE book Page 38 Friday May 6 200...

Page 110: ... all control 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 ca...

Page 111: ...f necessary gradually let off the throttle and or steer to the outside of the turn See pages 7 22 7 23 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 stil...

Page 112: ...er 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 pages 7 34 7 36 WARNING _ Indicates...

Page 113: ...inyl 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 1 Owner s manual 2 Owner s tool kit 3 Low pressure tire gauge 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 can start fire...

Page 114: ...a 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 installation or use of acc...

Page 115: ... require special tools data and technical skills _ ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 300 800 2 500 1 600 2 500 1 600 5 000 3 200 hours 20 80 160 160 320 Fuel line Check fuel hose for cracks or damage Replace if necessary Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Carburetor Ch...

Page 116: ...r oil Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months Front brake Check operation fluid leakage See NOTE page 8 5 Correct if necessary Rear brake Check operation fluid leakage See NOTE page 8 5 Correct if necessary Select lever safety system cable Check operation Adjust if necessary V belt Check operation Check for cracks or damage Wheels Check balance dama...

Page 117: ...y or death Rear upper and lower knuckle pivots Lubricate with lithium soap based grease Drive shaft universal joint Lubricate with lithium soap based grease Engine mount Check for cracks or damage Front and rear axle boots Check operation Replace if damaged Stabilizer bushes Check for cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and s...

Page 118: ...strated 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 EE book Page 6 Friday May 6 2005 8 59 AM ...

Page 119: ...8 7 EBU00700 Panel A D To remove 1 Remove the seat 2 Pull outward on the areas shown and then pull upward EE book Page 7 Friday May 6 2005 8 59 AM ...

Page 120: ...8 8 To install 1 Place the panel in its original position 2 Install the seat EE book Page 8 Friday May 6 2005 8 59 AM ...

Page 121: ...osition and in stall the bolt CAUTION _ When installing the panel be sure not to pinch the cables or wires _ 1 Bolt 2 Panel B EBU15370 Panel C To remove 1 Remove the top carrier bolts 1 Carrier bolt 4 top 2 Remove the carrier bolts under the fend ers and then take the carrier off EE book Page 9 Friday May 6 2005 8 59 AM ...

Page 122: ...ition and then install the quick fastener screws 2 Place the carrier in the original position and then install the carrier bolts under the fenders 3 Install the top carrier bolts and then tight en all bolts to the specified torques Tightening torque Carrier bolt top 34 Nm 3 4 m kgf 24 ft lbf Carrier bolt under fenders 7 0 Nm 0 7 m kgf 5 1 ft lbf EE book Page 10 Friday May 6 2005 8 59 AM ...

Page 123: ... 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 EBU00638 Panel F To remove Pull outward on the areas shown 1 Panel F EE book Page 11 Friday May 6 2005 8 59 AM ...

Page 124: ...vals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Remove panel F See pages 8 11 8 12 for panel removal 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 clea...

Page 125: ...d be between the mini mum and maximum level marks _ 1 Maximum level mark 2 Minimum level mark 7 If the engine oil is at or below the mini mum level mark add sufficient oil of the recommended type to raise it to the cor rect level 8 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 9 Install the panel EE book Page 13 Friday May 6 2005 8 59 AM ...

Page 126: ...gine 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 the crankcase 1 Engine oil drain bolt NOTE _ Skip steps 5 9 if the oil filter cartridge is not being replaced _ 5 Remove panels D and E See pages 8 7 8 8 8 11 for panel removal and in stallation procedures 6 Remove the oil filter cartridge with an oil filter wrench 1 En...

Page 127: ...e O ring of the new oil filter cartridge NOTE _ Make sure the O ring is seated properly _ 1 O ring 8 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf EE book Page 15 Friday May 6 2005 8 59 AM ...

Page 128: ...mix any chemical additives Do not use oils with a diesel specification of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacem...

Page 129: ...el F EBU15380 Final gear oil Checking the final gear oil level 1 Place the ATV on a level surface 2 Remove the oil filler bolt and then check the oil level in the final gear case NOTE _ The oil level should be at the brim of the filler hole _ 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 1 Final gear oil filler bolt 2 ...

Page 130: ... final gear oil 1 Remove the engine guard and the final gear case guard by removing the bolts 1 Engine guard 2 Final gear case guard 3 Bolt 11 2 Place the ATV on a level surface 3 Place a container under the final gear case to collect the used oil Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf EE book Page 18 Friday May 6 2005 8 59 AM ...

Page 131: ...reign material enters the final gear case _ 7 Install the oil filler bolt and then tighten it to the specified torque 8 Check for oil leakage If oil leakage is found check for the cause Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 16 L 0 14 Imp qt 0 17 US qt Tightening torque Final gear oil filler bolt 23 Nm 2 ...

Page 132: ...he 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 2 Differential gear oil filler bolt 3 Correct oil level Tightening torques Engine guard bolt 7 0 Nm 0 7 m kgf 5 1 ft lbf Final gear case guard bolt 7 0 Nm 0 7 m kgf 5 1 ...

Page 133: ...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 ommended oil Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf Tightening torque D...

Page 134: ... 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 _ 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 23 L 0 20 Imp qt 0 24 US qt Tightening torque Differenti...

Page 135: ...mful to 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 62 for de tails Coolant reservoir capacity u...

Page 136: ...revent coolant from spilling on the foot rest 1 Coolant drain bolt 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...

Page 137: ...res 5 Remove the radiator cap 1 Radiator cap 6 Remove panel D See pages 8 7 8 8 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 EE book Page 25 Friday May 6 2005 8 59 AM ...

Page 138: ...mum 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 Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze and water mixing ratio 1 1 Total amount 1 30 L...

Page 139: ...the radiator 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 Front axle boot 2 each side EE boo...

Page 140: ...t 2 each side EBU00864 Spark plug inspection Removal 1 Remove panel A See pages 8 7 8 8 for panel removal and installation proce dures 2 Remove the spark plug cap 1 Spark plug cap EE book Page 28 Friday May 6 2005 8 59 AM ...

Page 141: ...ot attempt to diagnose such problems yourself Instead take the ATV to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes ex cessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Installation 1 Measure the el...

Page 142: ...que wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible _ 4 Install the spark plug cap 5 Install the panel Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf EE book Page 30 Friday May 6 2005 8 59 AM ...

Page 143: ...n the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seat See pages 4 20 4 21 for seat removal and installation proce dures 2 Remove the air filter case cover by un hooking the fasteners 1 Fastener 4 2 Air filter case cover 3 Remove the air filter element assembly 1 Air filter element assembly EE book Page 31 Friday May 6 2005 8 59 AM ...

Page 144: ...lement and let it dry CAUTION _ Do not twist the air filter element when squeezing it _ 7 Inspect the air filter element and replace it if damaged 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 HAZARD Use parts cleaning solvent to clean the air filte...

Page 145: ... machine is operated in extremely dusty areas Each time the air filter element maintenance is performed check the air inlet to the filter case for obstructions Check the air filter case rubber joint to the car buretor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine _ CAUTION _ Never operate the engine with the ...

Page 146: ...side of ATV EBU08741 V belt case drain plug After riding in water deep enough to allow it to enter the V belt case remove this plug to drain the water from the case NOTE _ If water drains from the V belt case after re moving the plug have a Yamaha dealer in spect the ATV as the water may affect other engine parts _ 1 V belt case drain plug EE book Page 34 Friday May 6 2005 8 59 AM ...

Page 147: ...t out of the muffler 1 Bolt 3 2 Tailpipe 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install and tighten the bolts EE book Page 35 Friday May 6 2005 8 59 AM ...

Page 148: ... many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning...

Page 149: ...ickly responds to the throttle 2 Remove panel D See pages 8 7 8 8 for removal and installation procedures 3 Connect the tachometer to the spark plug lead and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction a to increase the engine speed and in direc tion b to decrease the engine speed 1 Throttle stop screw 4 Install the panel Specifi...

Page 150: ...ment however should be left to a professional Yamaha service technician EBU00307 Throttle lever adjustment NOTE Adjust the engine idling 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 0 5 0 mm 0 12 0 20 in 3 Tighten the locknut 1 Locknut 2 Adjusting bolt a Throttle lever free play EE book Page 38 Friday M...

Page 151: ...ustment however should be left to a Yamaha dealer EBU13090 Front brake pad check Check the brake pads for damage and wear If a brake pad thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the pads as a set a Brake pad thickness NOTE _ The wheels need to be removed to check the brake pads See pages 8 49 8 50 for remov al and installation procedures _ EE book Page 39 Friday May 6 200...

Page 152: ...mbling 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 1 Brake pad wear indicator groove NOTE _ The wheels need to be removed to check the brake pads See pages 8 49 8 50 for wheel removal and installation procedures _ EE book Page 40 Friday May 6 2005 8 59 AM ...

Page 153: ...nish 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 moval and installation procedures 1 Minimum level mark 1 Minimum level mark FRONT REAR E...

Page 154: ... refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfac es or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer check the cause if the brake fluid level goes down EBU11860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel Have ...

Page 155: ...ted 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 Replacement of brake components re quires professional knowledge These procedures shou...

Page 156: ...ar brake lever free play 2 Turn the adjusting bolt in direction a to increase free play and in direction b to decrease free play 3 Tighten the locknut If correct free play cannot be obtained ask a Yamaha dealer to make that adjustment NOTE _ When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move _ EE book Page 44 Friday May 6 20...

Page 157: ...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 All air must be bled from the brake system Replacement of brake components re quires professional knowledge These procedures should be performed by a Yamaha ...

Page 158: ...the brake light switch as follows 1 Remove panel B See page 8 9 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 ...

Page 159: ...stallation procedures _ WARNING 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 Yamaha chain an...

Page 160: ...ckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun 1 Upper knuckle 2 Lower knuckle Recommended lubricant Lithium soap based grease EE book Page 48 Friday May 6 2005 8 59 AM ...

Page 161: ... 4 Remove the wheel 1 Nut 4 EBU11211 Wheel installation 1 Install the wheel and the nuts NOTE _ The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its ta pered side towards the wheel _ 1 Arrow mark EE book Page 49 Friday May 6 2005 8 59 AM ...

Page 162: ...with a sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the bat tery If the battery seems to have discharged consult a Yamaha dealer 1 Negative battery terminal 2 Positive battery terminal Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf EE book Page 50 Friday May 6 2005 8 59 AM ...

Page 163: ...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 and get prompt medical attention Keep batteries away from sp...

Page 164: ...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 EBU08762 Fuse replacement 1 The main fuse and the fuse box are locat ed under the seat 2 If a fuse is blown turn off the main switch and the switch of the circuit in question Then install a new fuse of the specified amperage Turn on t...

Page 165: ...our wheel drive fuse 5 Signaling system fuse 6 Backup fuse for odometer and clock 7 Spare fuse 3 Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Four wheel drive fuse 3 0 A Signaling system fuse 10 0 A Backup fuse 10 0 A EE book Page 53 Friday May 6 2005 8 59 AM ...

Page 166: ...ove the 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 EE book Page 54 Friday May 6 20...

Page 167: ... coupler 3 Remove the headlight bulb holder as sembly by turning it counterclockwise 1 Headlight bulb holder assembly NOTE _ The headlight bulb cannot be removed from the headlight bulb holder To replace the headlight bulb replace the headlight bulb holder assembly _ EE book Page 55 Friday May 6 2005 8 59 AM ...

Page 168: ...lb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner _ 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 ...

Page 169: ...light EBU01089 Headlight beam adjustment CAUTION _ It is advisable to have a Yamaha dealer make this adjustment _ To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b 1 Headlight beam adjusting screw EE book Page 57 Friday May 6 2005 8 59 AM ...

Page 170: ...brake light unit 2 Nut 2 2 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Tail brake light unit 2 Tail brake light bulb holder 3 Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise EE book Page 58 Friday May 6 2005 8 59 AM ...

Page 171: ... prob lem in the fuel compression or ignition sys tems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it to a Yamaha dealer The skilled technicians at a Yamaha dealer ship have the tools experience and know how to properly service your machine Use only genuine Yamaha parts on your machi...

Page 172: ...AN HAPPEN Fuel can ignite or explode causing se vere injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnac es EE book Page 60 Friday May 6 2005 8 59 AM ...

Page 173: ...Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the 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 or replace the spark plug No spark Ask a Yamaha dealer to inspect 4 Battery Use the electric starter Engine turns over quickly Battery...

Page 174: ...ARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag over 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 th...

Page 175: ...l 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 ers 4 Once th...

Page 176: ...es which may mar the paint 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 ...

Page 177: ...2 Remove the spark plug pour about one tablespoon 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 en...

Page 178: ... in a dry 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 EE book Page 4 Friday May 6 2005 8 59 AM ...

Page 179: ...rance 245 mm 9 65 in Minimum turning radius 3 000 mm 118 1 in Basic weight With oil and full fuel tank 285 0 kg 628 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 421 0 cm3 Bore stroke 84 5 75 0 mm 3 33 2 95 in Compression ratio 10 00 1 Starting system Electric and recoil starter Lubrication system Wet sump EE book Page 1 Friday...

Page 180: ... US qt Model YFM45FAV 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 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 E...

Page 181: ...ty 0 23 L 0 20 Imp qt 0 24 US qt Radiator capacity including all routes 1 30 L 1 14 Imp qt 1 37 US qt Air filter Wet type element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 15 0 L 3 30 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 YFM45FAV EE book Page 3 Friday May 6 2005 8 59 AM ...

Page 182: ...m Shaft drive 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 2 5 Trail 8 5 mm 0 33 in Tire Type Tubeless Size front AT25 8 12 rear AT25 10 12 Model YFM45FAV EE book Page 4 Friday May 6 2005 8 59 AM ...

Page 183: ...nsion Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 160 0 mm 6 30 in Rear wheel travel 180 0 mm 7 09 in Electrical Ignition system DC C D I Generator system A C magneto Battery type YTX20L BS Battery capacity 12 V 18 0 Ah Headlight type Krypton bulb Model YFM45FAV EE book Page 5 Friday May 6 200...

Page 184: ...erature 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 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Four wheel drive fuse 3 0 A Signaling system fuse 10 0 A Backup fuse 10 0 A Model YFM45FAV EE book Page 6 Friday May 6 2005 8 59 AM ...

Page 185: ...e purpose 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 syst...

Page 186: ... that the maintenance work is required It is not acceptable proof of maintenance work ACL 07E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 300 800 80 6 2 500 1 600 160 12 5 000 3 200 320 18 7 500 4 800 480 24 10 000 6 400 640 30 12 500 8 000 800 36 15 000 9 600 960 42 17 500 11 200 1 120 48 20 000 12 800 1 280 54 22 500 1...

Page 187: ...13 1 EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY E 13 fm Page 1 Monday August 8 2005 4 27 PM ...

Page 188: ...13 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EE book Page 2 Friday May 6 2005 8 59 AM ...

Page 189: ...14 1 EBU00435 YAMAHA EXTENDED SERVICE Y E S EE book Page 1 Friday May 6 2005 8 59 AM ...

Page 190: ...14 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00436 WARNING _ Indicates a potential hazard that could result in serious injury or death EE book Page 2 Friday May 6 2005 8 59 AM ...

Page 191: ...EBU00437 EE book Page 3 Friday May 6 2005 8 59 AM ...

Page 192: ...pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND PROT...

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