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Yamaha RHINO YXR45FW, Owner'S Manual

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Yamaha RHINO YXR45FW Owner'S Manual Download Page 62

5-7

EVU00430

Final gear oil

Make sure the final gear oil is at the specified
level. Add oil as necessary. (See pages 8-14–
8-15 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. 

_ 

EVU00440

Differential gear oil

Make sure the differential gear oil is at the
specified level. Add oil as necessary. (See
pages 8-16–8-17 for details.)

EVU00450 

Accelerator pedal

Check to see that the accelerator pedal oper-
ates correctly. It must operate smoothly and
fully spring back to the idle position when re-
leased. Have a Yamaha dealer repair as nec-
essary for proper operation.

EVU00460

Seat belts 

Make sure that both seat belts are not frayed
or damaged.
The seat belt must move smoothly when
pulled out and retract on its own when re-
leased. The latch plate should click securely
into the buckle and release when the release
button is pushed firmly. Wash off any dirt or
mud which could affect operation. Have a
Yamaha dealer repair as necessary for proper
operation.

Recommended oil:

SAE 80 API GL-4 Hypoid gear oil

Recommended oil:

SAE 80 API GL-5 Hypoid gear oil 

EE.book  Page 7  Wednesday, August 2, 2006  5:10 PM

Summary of Contents for RHINO YXR45FW

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL ...

Page 2: ...EBU00776 ...

Page 3: ...f the features and operation of this vehicle It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your vehicle please consult a Yamaha dealer WARNING _ Please read this manual carefully before operating this vehicle Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and operat...

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

Page 5: ... choosing where to operate this vehicle It is illegal to operate this vehicle on public lands where vehicles its size are prohibited This vehicle complies with almost all state off highway noise level and spark arrester laws and regulations EVU00040 YXR45FW OWNER S MANUAL 2006 by Yamaha Motor Corporation U S A 1st edition July 2006 All rights reserved Any reprinting or unauthorized use without the...

Page 6: ...itch 4 1 Indicator and warning lights 4 3 Indicator and warning lights 1 2 3 4 Brake pedal 4 16 Parking brake lever 4 17 Drive select lever 4 18 Fuel tank cap 4 18 Fuel level check window 4 19 Starter choke 4 19 Seats 4 20 Seat belts 4 21 Glove compartment 4 23 Cargo bed 4 23 Front and rear shock absorber adjustment 4 26 Trailer hitch bracket 4 28 Auxiliary DC jack 4 29 PRE OPERATION CHECKS 5 1 Fr...

Page 7: ...5 Engine break in 6 7 Parking 6 9 Learning to operate your vehicle 7 5 Turning your vehicle 7 6 Braking 7 7 Going uphill 7 7 Going downhill 7 9 Crossing through shallow water 7 11 Riding over rough terrain 7 13 Riding in brush or wooded areas 7 14 Encountering obstacles on the trail 7 15 PERIODIC MAINTENANCE AND ADJUSTMENT 8 1 Owner s manual and tool kit 8 1 Periodic maintenance chart for the emis...

Page 8: ...e fluid level 8 34 Brake fluid replacement 8 35 Checking the brake pedal 8 35 Parking brake lever free play adjustment 8 36 Rear knuckle upper and lower pivot lubrication 8 40 Steering shaft lubrication 8 40 Wheel removal 8 41 Wheel installation 8 41 Battery 8 42 Battery maintenance 8 43 Fuse replacement 8 44 Replacing a headlight bulb 8 46 Headlight beam adjustment 8 49 Tail brake light bulb repl...

Page 9: ...MAINTENANCE RECORD 12 1 YAMAHA MOTOR CORPORATION U S A SIDE SIDE VEHICLE LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 12 13 14 EE book Page 4 Wednesday August 2 2006 5 10 PM ...

Page 10: ...EVU00060 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS EE book Page 1 Wednesday August 2 2006 5 10 PM ...

Page 11: ...n all foreseeable accidents including rollover 2 WARNING IMPROPERTIREPRESSUREOROVERLOADINGCANCAUSE LOSSOFCONTROL LOSSOFCONTROLCANRESULTINSEVEREINJURYOR DEATH OPERATING TIRE PRESSURE Set with tires cold RECOMMENDED FRONT 70kPa 70kgf cm 10psi REAR 98kPa 98kgf cm 14psi MINIMUM FRONT 63kPa 63kgf cm 9psi REAR 91kPa 91kgf cm 13psi Never set tire pressure below minimum Tire may dislodge from rim Gross Ve...

Page 12: ...Never carry passengers in cargo bed Cargo can affect handling and stability Read Owner s Manual before loading or towing When loading with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Be sure cargo is secured a loose load could change handling unexpectedly Keep weight in the cargo bed centered and as low and far forward as possible EE book Page 3...

Page 13: ...kg 110 lbs tongue weight on the towing bracket Do not tow more than 550kg 1212 lbs rolling weight trailer plus cargo Operate in low range gears only allow for increased braking distance and use extreme caution when operating on inclines Read carefully the loading information and trailer hitch sections in the owner s manual WARNING EE book Page 4 Wednesday August 2 2006 5 10 PM ...

Page 14: ...id motor vehicle license Adults must supervise use by minors Check state laws for minimum age requirements Gross Vehicle Weight Rating 2000 lb 907 kg maximum including operator passenger accessories cargo and ALWAYS wear a seat belt when riding in the vehicle keep your hands and feet inside the vehicle at all times watch for branches brush or other hazards that could enter the vehicle drive straig...

Page 15: ...9 0 EE book Page 6 Wednesday August 2 2006 5 10 PM ...

Page 16: ...belts Never give a ride to a passenger who is too small to reach and hold the handgrip on the enclo sure Always avoid operating the vehicle on any paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on any public street road or highway even a dirt or gravel one Never operate this vehicle without wearing an approved motorcycle helmet that fits properly Y...

Page 17: ...er wrap your thumbs and fingers around the steering wheel This is particularly important when driving in rough terrain The front wheels will move right and left as they respond to the terrain and this movement will be felt in the steering wheel A sudden jolt could wrench the steering wheel around and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes Always...

Page 18: ...for obstacles before operating in a new area Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model 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 no obstacles or people behind you when you operate in reverse...

Page 19: ...other sources of ignition such as the pi lot lights of water heaters and clothes dryers When transporting the vehicle in anoth er vehicle be sure it is kept in an upright position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get...

Page 20: ... 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 vehicle in an area with adequate ventilation EE book Page 5 Wednesday August 2 2006 5 10 PM ...

Page 21: ...EE book Page 6 Wednesday August 2 2006 5 10 PM ...

Page 22: ...ting ring 3 Brake fluid reservoir 4 Air filter element engine and air intake duct 5 V belt case 6 Driver seat 7 Driver seat belt 13 Spark arrester 14 Passenger seat belt 15 Passenger seat 16 Oil filter cartridge 17 Engine oil dipstick 18 Battery 19 Fuses EE book Page 1 Wednesday August 2 2006 5 10 PM ...

Page 23: ...e 27 Main switch 28 On Command four wheel drive and differential gear lock switches 29 Indicator and warning lights 30 Multi function meter unit special edition models 31 Auxiliary DC jack 32 Drive select lever 33 Parking brake lever EE book Page 2 Wednesday August 2 2006 5 10 PM ...

Page 24: ...amaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER ACA 02E 2 VEHICLE IDENTIFICATION NUMBER ACA 02E 3 MODEL LABEL INFORMATION EVU00100 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 3 Wednesday August 2 200...

Page 25: ...vehicle identification number is used to identify your vehicle _ EVU00121 Model label The model label is affixed to the frame under the driver seat Record the information on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label EE book Page 4 Wednesday August 2 2006 5 10 PM ...

Page 26: ... are supplied with power and the headlights and taillights come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position START The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts EE book Page 1 Wednesday August 2 2006 5 10 PM ...

Page 27: ... occur Wait at least 5 seconds between each operation of the electric starter to let it cool Do not turn the key to the START position with the engine running or damage to the electric starter can re sult See starting instructions prior to start ing the engine See pages 6 1 6 3 for details _ EE book Page 2 Wednesday August 2 2006 5 10 PM ...

Page 28: ...ke indicator light P This indicator light comes on when the park ing brake is applied EVU00160 Reverse indicator light R This indicator light comes on when the drive select lever is in the R reverse position NOTE _ If the indicator light flashes while riding have a Yamaha dealer check the speed sensor cir cuit _ EVU00170 Neutral indicator light N This indicator light comes on when the drive select...

Page 29: ...osition EVU00181 Coolant temperature warning light When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the light comes on during operation stop the en gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes See page 8 54 CAUTION _ The engine may overheat if the vehicle is overloaded If this...

Page 30: ...ight comes on Coolant temperature warning light does not come on Coolant temperature and electrical circuit are OK Go ahead with riding Turn the main switch to START with the transmission in the neutral position Ask a Yamaha dealer to inspect the electrical circuit Coolant temperature warning light comes on momentarily EE book Page 5 Wednesday August 2 2006 5 10 PM ...

Page 31: ...al gear lock indica tor light DIFF LOCK This indicator light and the On Command dif ferential gear lock indicator in the display come on when the On Command differential gear lock switch is set to the LOCK position NOTE _ When the switch is set to LOCK the On Command differential gear lock indicator light will flash until the differential gear is locked _ EVU01140 Low range indicator light L This ...

Page 32: ...or circuit _ EVU00210 EVU01161 On Command four wheel drive differential gear lock indicator The On Command four wheel drive indicator comes on when the On Command four wheel drive switch is set to the 4WD posi tion The On Command differential gear lock indi cator in the On Command four wheel drive indicator also comes on when the On Command differential gear lock switch is set to the LOCK position...

Page 33: ... _ The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine _ EVU01630 Multi function meter unit special edition models 1 Speedometer 2 Fuel meter 3 H button 4 M button 5 Clock Hour meter 6 Odometer Tripmeter A Tripmeter B 7 TRIP ODO butt...

Page 34: ...modes A and B in the fol lowing order ODO TRIP A TRIP B ODO To reset a tripmeter select it by pushing the TRIP ODO button and then push the TRIP ODO button for at least three seconds The tripmeters can be used to estimate the dis tance that can be traveled with a full tank of fu el This information will enable you to plan future fuel stops NOTE _ Holding in the TRIP ODO button and then turning the...

Page 35: ...hing the H button 4 Set the minutes by pushing the M but ton 5 Push the button and then re lease 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 refuel as soon as possible 1 ...

Page 36: ...and the taillights Set the switch to OFF to turn off all the lights CAUTION _ Do not use the headlights with the engine turned off for an extended period of time The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it _ L H L H L H EE book Page 11 Wednesday August 2 2006 5 10 PM ...

Page 37: ...ifferential gear lock switch 4WD LOCK Select the appropriate drive accord ing to terrain and the conditions Four wheel drive 4WD Power is sup plied 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 differ ential gear is locked DIFF LOCK Unlike the 4WD mode all wheels turn at the same speed regardless of ...

Page 38: ...Changing from 2WD to 4WD or from 4WD to 4WD LOCK DIFF LOCK or vice versa while the vehicle is moving WHAT CAN HAPPEN The vehicle 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 vehicle to unexpectedly handle differ ently This could distract the operator and increase the risk of lo...

Page 39: ...r unit display will come on To release the differential gear lock stop the vehicle and set the switch to 4WD WARNING POTENTIAL HAZARD Riding too fast while the vehicle 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 vehicle The amount of effort required is greater the faster you go You may lose control and have an...

Page 40: ...ndicator light will flash until the differential gear is locked When the indicator and indicator light are flashing turning the steering wheel back and forth will help the differential gear lock to engage Riding before the differential gear lock is EVU00260 Accelerator pedal Press the accelerator pedal down to increase engine speed Spring pressure returns the pedal to the rest position when releas...

Page 41: ...e 1 Brake pedal WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal WHAT CAN HAPPEN The accelerator pedal 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 accelerator pedal before you start the engine If it does not work smoothly check for the cause Correct the problem be...

Page 42: ...se the parking brake pull up on the lever press the release button and then push the lever all the way down Spring pressure helps return the lever to the released position Be sure to fully release the parking brake be fore starting out Failure to do so may result in poor performance and premature wearing of the rear brake and V belt 1 Parking brake lever 2 Release button EE book Page 17 Wednesday ...

Page 43: ...hicle into the low high neutral and reverse positions Refer to pages 6 5 6 7 for the drive select lever operation 1 Drive select lever EVU00300 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap EE book Page 18 Wednesday August 2 2006 5 10 PM ...

Page 44: ...1 Fuel level check window EVU00320 Starter choke Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See pages 6 1 6 3 EE book Page 19 Wednesday August 2 2006 5 10 PM ...

Page 45: ...ll a seat insert the projections on the rear of the seat into the seat holders and push down on the seat at the front WARNING POTENTIAL HAZARD A loose seat WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched EE book Page 20 Wednesday August 2 2006 5 10 PM ...

Page 46: ...2 To wear the seat belt properly do the follow ing 1 Hold the latch plate as you pull the belt across your lap and chest Make sure the belt is not twisted and is not caught on any portion of the vehicle your clothing or any equipment you are carrying 2 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure EE book Page 21 Wednesday August 2 2006 5...

Page 47: ...ll the belt out all the way and then let it retract 5 To release the buckle firmly press the re lease button WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle Be sure the seat belt is close fittin...

Page 48: ...ot put metal products like tools or sharply edged prod ucts directly in the glove compartment If they must be stored wrap them in appro priate cushion material _ EVU00351 Cargo bed 1 Cargo bed 2 Tailgate 3 Cargo hook 4 EE book Page 23 Wednesday August 2 2006 5 10 PM ...

Page 49: ...riginal position and then hook the latches Lifting and lowering the cargo bed 1 Cargo bed release lever To lift Push down the cargo bed release lever on the left or right side of the vehicle and then slowly lift up the cargo bed until it stops To lower Lower the cargo bed slowly to its original posi EE book Page 24 Wednesday August 2 2006 5 10 PM ...

Page 50: ...d fingers away from the pinch points between the bed and the frame WARNING POTENTIAL HAZARD Overloading the cargo bed 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 maximum load limit for this cargo bed Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Al low greater ...

Page 51: ...Adjust the spring preload as follows To increase the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall be thrown out or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo b...

Page 52: ...g ring 2 Position indicator NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ 1 Special wrench Standard position B A Minimum soft E Maximum hard EE book Page 27 Wednesday August 2 2006 5 10 PM ...

Page 53: ...es 6 11 6 13 for precaution information 1 Trailer hitch bracket 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 28 Wednesday August 2 2006 5 10 PM ...

Page 54: ...The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A EE book Page 29 Wednesday August 2 2006 5 10 PM ...

Page 55: ...the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may be come difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged _ EE book Page 30 Wednesday August 2 2006 5 10 PM ...

Page 56: ...ill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 5 8 10 8 13 Coolant reservoir Check coolant level Fill with coolant if necessary 5 6 8 18 8 19 Final gear oil Differential gear oil Check for leakage 5 7 8 14 8 17 Accelerator pedal Check for proper accelerator pedal operation 5 7 Seat belts Check for proper operation and belt wear 5 7 Steering Check for pro...

Page 57: ...rake fluid level Check the brake fluid level Add fluid if necessary See pages 8 34 8 35 WARNING POTENTIAL HAZARD Failure to inspect the vehicle before op erating Failure to properly maintain the vehicle WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating c...

Page 58: ...ot provide proper braking per formance inspect the brake system See pages 8 32 8 36 WARNING POTENTIAL HAZARD Driving 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 operate the vehicle if you find any problem with the brakes If a problem cannot be correc...

Page 59: ... 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 Gasohol There are two types of gasohol gasohol con taining ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gaso hol containing methanol is not recommended by Yamaha...

Page 60: ...igher Make sure that no foreign material en ters the crankcase _ WARNING POTENTIAL 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 espec...

Page 61: ...lled water Change the coolant every two years See pages 8 18 8 19 for details CAUTION _ Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water _ 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...

Page 62: ...hat the accelerator pedal oper ates correctly It must operate smoothly and fully spring back to the idle position when re leased Have a Yamaha dealer repair as nec essary for proper operation EVU00460 Seat belts Make sure that both seat belts are not frayed or damaged The seat belt must move smoothly when pulled out and retract on its own when re leased The latch plate should click securely into t...

Page 63: ...ation EVU00470 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the vehicle to a Yamaha dealer or refer to the Service Manual for correct tightening torque EVU00480 Lights Check the headlights and tail brake lights to make sure they are in working condition Re pair as necessary for proper operation EE book Page 8 Wednesday August 2 2006 5 10 PM...

Page 64: ...Motor Manufac turing corporation of America for this model Other tire combinations 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 70 kPa 0 70 kgf cm2 10 psi Rear 98 kPa 0 98 kgf cm2 14 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to disl...

Page 65: ...owing specifica tions ACE 02E 4 Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst Recommended pressure Minimum Maximum Front 70 kPa 0 70 kgf cm2 10 psi 63 kPa 0 63 kgf cm2 9 psi 77 k...

Page 66: ...1 Tire pressure gauge EVU00520 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 Wednesday August 2 2006 5 10 PM ...

Page 67: ...ccident 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 vehi cle which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all co...

Page 68: ...o neutral before starting the engine _ 3 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warm Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 4 With your foot off...

Page 69: ...this position to warm up the engine 6 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding EVU00550 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used Press the accelerator pedal slightly EVU00561 Jump starting Jump starting the vehicle should be avoided The batter...

Page 70: ...ead of the jumper cable to the negative terminal of the battery in the vehicle Be especially careful not to touch the positive lead of the jump er cable to the negative lead reverse the polarity of the jumper cables when connecting to the bat teries battery explosion and or se rious damage to the electrical system may occur _ 6 Start the engine Refer to Starting a cold engine on pages 6 1 6 3 7 Af...

Page 71: ...eration and reverse driving CAUTION _ Before shifting you must stop the vehicle and take your foot off the accelerator ped al Otherwise the transmission may be damaged _ Shifting Neutral to High and High to Low 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...

Page 72: ...ng the drive select lever along the shift guide 1 Drive select lever NOTE _ When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the reverse indicator light electrical cir cuit Due to the synchronizing mechanism in the engine the light may not come on un EE book Page 6 Wednesday August 2 2006 5 10 PM ...

Page 73: ...in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition 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 WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an...

Page 74: ...ealer 0 10 hours Avoid continuous operation above half throt tle Allow a cooling off period of five to ten min utes after every hour of operation Vary the speed of the vehicle from time to time Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the vehicle freely but do not use full throt tle at any time After break in The vehicle can now be...

Page 75: ...a hill or other incline WHAT CAN HAPPEN The vehicle 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 apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the vehicle at all on hills that are so steep you could not walk up them easily EE book ...

Page 76: ...eep the following in mind when considering an accessory or operating a vehicle which has accessories Choose only accessories designed for your vehicle Your Yamaha dealer has a variety of genuine Yamaha accessories Other ac cessories may also be available on the market However it is not possible for Yamaha to test all non Yamaha accesso ries nor have any control over the quality or suitability of t...

Page 77: ...e vehicle may handle differently than it does without accessories EVU00630 Loading Cargo or a trailer can change the stability and handling of a vehicle You must use common sense and good judg ment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An overloaded vehicle can be unstable MAXIMUM LOADING LIMIT Vehicle loading limit total wei...

Page 78: ...t down using the cargo hooks equipped on the cargo bed Tie down cargo securely in the trailer Make sure cargo in the trailer cannot move Make sure the load does not interfere with controls or your ability to see where you are going Drive more slowly than you would without a load The more weight you carry the slow er you should go Although conditions vary it is good practice not to exceed low range...

Page 79: ...in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking EE book Page 13 Wednesday August 2 2006 5 10 PM ...

Page 80: ... read all caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry passengers in the cargo bed WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW TO AVOID THE ...

Page 81: ... on page 6 11 Car rying a passenger and cargo can affect vehi cle handling WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed The cargo bed is designed to carry cargo only EE book Page 2 Wednesday August 2 2006 5 10 PM ...

Page 82: ...verloading this vehicle or carrying or towing 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 vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the ins...

Page 83: ...re head injury or death in the event of an ac 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 HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants EE book Page 4 W...

Page 84: ...more difficult ma neuvers Perform the Pre Operation Checks on pages 5 1 5 11 Set the parking brake shift to neu tral and follow the instructions on page 6 1 to start the engine Once it has warmed up and you have turned the choke off you are ready to begin driving your vehicle With the engine idling shift the drive select lever into low or high Then release the parking brake Press the accelerator p...

Page 85: ...ou attempt sharp high speed turns You should also be careful making sharp turns on rough terrain Do not attempt to turn around or make abrupt maneuvers on Position your hands on the steering wheel so that your thumbs and fingers do not wrap around the wheel This is particularly impor tant when driving in rough terrain The front wheels will move right and left as they re spond to the terrain and th...

Page 86: ...d basic maneuvers on flat ground Use proper driving techniques to avoid over turns on hills and slopes Drive straight up hills and avoid crossing the side of a hill which increases your chance of rollover Practice first on gentle slopes before attempt ing steeper hills Always check the terrain carefully before attempting any hill Use com Choose carefully which hills you attempt to climb Avoid hill...

Page 87: ... is on the other side there could be another person an ob stacle or a sharp drop off WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small hills HOW TO AVOID THE HAZARD Never operate your vehicle on hills too steep for it or your abilities Never oper ate vehicles on hills steeper ...

Page 88: ...ry to slow your de scent Release the brake and begin to coast down the hill Use engine braking as much as possible gently applying the brakes when necessary GOING DOWNHILL Check the terrain carefully before going down a hill When possible choose a path that lets you drive your vehicle straight downhill Avoid sharp angles that could allow the vehicle to pitch or roll over Carefully choose your path...

Page 89: ...an obsta cle do so slowly and carefully If the vehicle starts to tip gradually steer in the downhill di rection if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you want to go WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn HOW TO AVOID THE HAZARD Always chec...

Page 90: ...essary apply the brakes several times to let friction dry out the linings WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPPEN Loss of control which could result in an accident including overturn which could increase the risk of drowning HOW TO AVOID THE HAZARD Never operate this vehicle in fast flow ing water or in water deeper than 33 cm 13 in Rememb...

Page 91: ...t the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hose and the V belt case drain plug Wash the vehi cle in fresh water if it has been operated in salt water or muddy conditions _ 1 Air filter case check hose EE book Page 12 Wednesday August 2 2006 5 10 PM ...

Page 92: ...Avoid jumping the vehi cle as injury loss of control and damage to the vehicle could occur WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle over turning or going out of control HOW TO AVOID THE HAZARD EE book Page 13 Wednesday Au...

Page 93: ...or obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger Nev er hold onto the enclosure so your hand is outside the vehicle Hold only onto the hand grip inside the enclosure EE book Page 14 Wednesday August 2 2006 5 10 PM ...

Page 94: ... maintain your momentum but still give yourself plenty of time to react to changes in conditions If there is any question about your ability to maneuver safely over the obstacle you should turn around if the ground is flat and you have the room or back up until you find a less difficult path WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or...

Page 95: ...Owner s manual and tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it on the bottom of the driver seat as shown Put the owner s tool kit and tire pressure gauge in the space beside the battery 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 compo...

Page 96: ...d minor re pairs The tools provided in the Owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts NOTE _ If you do not have a torque wrench available during a service operation requiring one take your vehicle to a Yamaha dealer to check the torque settings and adjust them as necessary _ EE book Page 2 Wednesday August 2 200...

Page 97: ...g which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through im proper installation or use of accesso ries All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this vehicle and should be in stalled and used according to instruc EE book Page 3 Wednesday August 2 2006 5 10 PM ...

Page 98: ... they require special tools data and technical skills ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 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...

Page 99: ...ining Engine oil filter cartridge Replace Final gear oil Check oil level oil leakage Replace Differential gear oil Front brake Check operation brake pad wear fluid leakage see NOTE page 8 6 Correct if necessary Replace pads if worn to the limit Rear brake Check operation brake pad wear fluid leakage see NOTE page 8 6 Correct if necessary Replace pads if worn to the limit Accelerator pedal Check op...

Page 100: ...cracked or damaged Drive shaft universal joint Lubricate with lithium soap based grease Engine mount Check for cracks or damage Check bolt tightness Front and rear axle boots Check operation Replace if damaged Stabilizer bushings Check for cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3...

Page 101: ...EVU00680 Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch 2 1 Hood EE book Page 7 Wednesday August 2 2006 5 10 PM ...

Page 102: ...on the back of the instru ment panel Secure slots 3 on the side of the hood around projections 4 on the frame 1 Projection 2 2 Slot 2 3 Slot 2 4 Projection 2 CAUTION _ Make sure that all cables and wires are in place when closing the hood Do not drive the vehicle with the hood open unlatched or removed _ EE book Page 8 Wednesday August 2 2006 5 10 PM ...

Page 103: ...1 Console To install 1 Place the console in its original position 2 Install the parking brake lever boot 3 Install the seats CAUTION _ When installing the console be sure not to pinch the cables or wires Make sure that the groove at the bot tom of the parking brake lever boot and the drive select lever boot fits se curely around the edge of the hole in the console _ EE book Page 9 Wednesday August...

Page 104: ...res 3 Check the engine oil level on a cold engine NOTE If the engine was started before checking the oil level be sure to warm up the engine suffi ciently and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the engine oil filler cap and wipe NOTE _ The engine oil should be between the mini mum and maximum level marks _ 1 Maximum level mark 2 Minimum level mark...

Page 105: ...oil pan under the engine to col lect the used oil and then remove the en gine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase NOTE _ Skip steps 5 7 if the oil filter cartridge is not being replaced _ 5 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter wrench NOTE _ An oil filter wrench is available at a nearby EE boo...

Page 106: ...rtridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Oil filter cartridge 2 Torque wrench 8 Install the engine oil drain bolt and then tighten it to the specified torque 9 Add the specified amount of recommend Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf EE book Page 12 Wednesday August 2 2006 5 10 PM ...

Page 107: ...tart the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 11 Turn the engine off wait at least ten min utes and then check the oil level and cor rect it if necessary 12 Install the console Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 2 50 L 2 20 I...

Page 108: ...l NOTE _ The oil level should be at the brim of the filler 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 CAUTION _ Be sure no foreign material enters the final gear case _ 4 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf EE ...

Page 109: ... bolt and then tighten it to 5 Add the recommended final gear oil up to the brim of the filler hole CAUTION _ Be sure no foreign material enters the final gear case _ 6 Install the oil filler bolt and then tighten it to the specified torque Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft l...

Page 110: ...iller bolt CAUTION _ Be sure no foreign material enters the dif ferential gear case _ 3 Install the differential gear oil filler bolt and then tighten it to the specified torque Changing the differential gear oil 1 Place the vehicle on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oi...

Page 111: ...all the differential gear oil filler bolt and then tighten it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Tightening torque Differential gear oil drain bolt 9 8 Nm 0 98 m kgf 7 1 ft lbf Recommended oil SAE 80 API GL 5 Hypoid gear oil Oil quantity 0 32 L 0 28 Imp qt 0 34 US qt Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft l...

Page 112: ... when the engine is cold as the coolant level varies with engine tempera ture NOTE _ The coolant should be between the minimum and maximum level marks _ 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 4 If the coolant is at or below the minimum level mark remove the reservoir cap add coolant to the maximum level mark install the reservoir cap and then close the hood Coolant reser...

Page 113: ...r instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant have a Yamaha dealer check the antifreeze con tent of the coolant as soon as possible The radiator fan is automatically switched on or off according to the coolant temper ature in the radiator EVU00740 Axle boots Check the protective boots for holes or tears If any damage is found have them replac...

Page 114: ... plug inspection Removal 1 Remove the console See page 8 9 for console removal and installation proce dures 2 Remove the spark plug cap 1 Spark plug cap 3 Use the spark plug wrench in the tool kit EE book Page 20 Wednesday August 2 2006 5 10 PM ...

Page 115: ...to light tan for a vehicle that is being ridden nor mally Do not attempt to diagnose such problems yourself Instead take the vehicle 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 th...

Page 116: ...ue wrench is not available when you are installing the spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past fin ger tight Have the spark plug tightened to the specified torque as soon as possible _ 4 Install the spark plug cap 5 Install the console Spark plug gap 0 6 0 7 mm 0 024 0 028 in Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf EE book Page 22 Wednesday Augu...

Page 117: ...r intake duct grill 2 Remove the air filter element from the air intake duct grill by pulling it out as shown 1 Air filter element 2 Air intake duct grill 3 Remove any large particles from the air filter element by hand 4 Tap the air filter element to remove most of the dust and dirt and then blow the re maining dirt out with compressed air EE book Page 23 Wednesday August 2 2006 5 10 PM ...

Page 118: ...k fastener screws Cleaning the engine air filter element NOTE _ There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seats See page 4 20 for EE book Page 24 Wednesday August 2 2006 5 10 PM ...

Page 119: ...lter case cover by un hooking the holders 1 Holder 5 2 Air filter case cover 4 Remove the air filter element 5 Remove the sponge material from its frame 1 Air filter element EE book Page 25 Wednesday August 2 2006 5 10 PM ...

Page 120: ...ld be wet but not dripping _ 10 Pull the sponge material over its frame 11 Install the air filter element 12 Install the air filter case cover by hooking the holders onto the air filter case 13 Install the console 14 Install the seats WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire...

Page 121: ...nt to the carburetor 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 air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration without the air filter element will af fect carbureto...

Page 122: ... EVU00780 V belt case drain plug The V belt case drain plug is located under the driver seat See page 4 20 for seat re moval and installation procedures After riding in water deep enough to allow wa ter to enter the V belt case remove the drain plug to drain any water from the case NOTE _ If water drains from the V belt case after re moving the drain plug have a Yamaha dealer inspect the vehicle a...

Page 123: ...ster Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the bolts 1 Bolt 3 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a EE book Page 29 Wednesday August 2 2006 5 10 PM ...

Page 124: ... 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 the spark arrester Always let the exhaust system cool pri or to touching exhaust components Do not start the engine when cleaning the exhaust system EE boo...

Page 125: ...ce and damage may result _ EVU00810 Idle speed adjustment NOTE _ A diagnostic tachometer must be used for this procedure _ 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Remove the seats See page 4 20 for seat removal and installation procedur...

Page 126: ...00830 Front brake pad check Each brake pad is provided with wear indica tor grooves which allow you to check the brake pad wear without having to disassem ble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indica tor grooves have almost disappeared have a Yamaha dealer replace the brake pads as a set EE book Page 32 Wednesd...

Page 127: ...provided with wear indica tor grooves which allow you to check the brake pad wear without having to disassem ble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indica tor grooves have almost disappeared have a Yamaha dealer replace the brake pads as a set EE book Page 33 Wednesday August 2 2006 5 10 PM ...

Page 128: ...hood opening and closing procedures Observe these precautions When checking the fluid level make sure the top of the brake fluid reservoir is level Use only the recommended quality brake fluid Otherwise the rubber seals may de teriorate causing leakage and poor braking performance Refill with the same type of brake fluid Mix ing fluids may result in a harmful chemical reaction and lead to poor bra...

Page 129: ...aintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years EVU01220 Checking the brake pedal Have a Yamaha dealer check the brakes at the intervals specified in the periodic mainte nance and lubrication chart There should be no free play in the brake pedal The brakes should operate smoothly and there should be no brake drag If the ...

Page 130: ...aximum free play is equal to one click of the parking brake lever If neces sary adjust the free play as follows WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the brake pedal position is correct Make su...

Page 131: ...ng the parking brake lever free play _ 5 Loosen the locknut 1 Locknut 2 Adjusting nut 6 Turn the adjusting nut in direction a to increase the free play or in direction b to decrease the free play 7 Tighten the locknut 8 Install the console 9 Install the seats EE book Page 37 Wednesday August 2 2006 5 10 PM ...

Page 132: ... switch as follows 1 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the ad justing nut in direction a To make the brake light come on later turn the adjust ing nut in direction b 1 Brake light switch 2 Adjusting nut 3 Close the hood EE book Page 38 Wednesday ...

Page 133: ...NING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Recommended lubricant Lithium soap based grease all purpose grea...

Page 134: ...nuckle upper and lower pivots with a grease gun EVU00920 Steering shaft lubrication Lubricate the pivot points Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease all purpose grease EE book Page 40 Wednesday August 2 2006 5 10 PM ...

Page 135: ...eel 4 Remove the wheel 1 Nut 4 EVU00940 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 _ EE book Page 41 Wednesday August 2 2006 5 10 PM ...

Page 136: ...illed water in the bat tery If the battery seems to have discharged consult a Yamaha dealer CAUTION _ Do not try to remove the sealing caps of the battery cells You may damage the bat tery _ Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WHAT CAN HAPPEN You could be poisoned You c...

Page 137: ...s are correct when putting the battery back in the vehicle HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for...

Page 138: ... the hood See pages 8 7 8 8 for hood opening and closing procedures If a fuse is blown turn off the main switch and install a new fuse of the specified amperage If a fuse is blown replace it as follows 1 Remove the battery compartment cover by lifting it up and pulling it out EE book Page 44 Wednesday August 2 2006 5 10 PM ...

Page 139: ...n on the electrical circuit in question to check if the device operates 5 If the fuse immediately blows again have a Yamaha dealer check the electrical system 6 Install the battery compartment cover 7 Close the hood Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Signaling system fuse 10 0 A Carburetor warmer fuse 10 0 A Four wheel drive mo...

Page 140: ...e rear of the headlight by pulling it off 1 Cover at the rear of the headlight 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 46 Wednesday August 2 2006 5 10 PM ...

Page 141: ... bulb holder cover by pulling it off 1 Headlight bulb holder cover 4 Remove the headlight bulb holder by pushing it in and turning it counterclock wise 1 Headlight bulb holder EE book Page 47 Wednesday August 2 2006 5 10 PM ...

Page 142: ... glass the luminos ity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool b...

Page 143: ...er is securely fitted over the bulb holder and seated properly 9 Close the hood 10 Adjust the headlight beam if necessary EVU00990 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 EE book Page 49 Wednesday August 2 2006 5 10 PM ...

Page 144: ...e light bulb burns out replace it as follows 1 Remove panel A if replacing the left tail brake bulb or panel B if replacing the right tail brake bulb by removing the quick fasteners and bolts 1 Panel A 1 Panel B EE book Page 50 Wednesday August 2 2006 5 10 PM ...

Page 145: ...e light bulb holder 3 Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder 4 Push a new bulb in and turn it clockwise to install in the bulb holder Tightening torque Panel bolt 6 5 N m 0 65 m kgf 4 7 ft lbf EE book Page 51 Wednesday August 2 2006 5 10 PM ...

Page 146: ...rience and know how to properly service your vehicle Use only genuine Yamaha parts on your vehicle Imita tion parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se ve...

Page 147: ...sion Ask a 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 4 Battery Use the electric starter Engine turns over quickly Battery is good Check the f...

Page 148: ...over the cap Allow any re maining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the coolant reservoir and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See NOTE Restart the engine If the engine overheats again as...

Page 149: ...to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION _ Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash ...

Page 150: ...e 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 out the linings EE ...

Page 151: ... from building up Pour the drained fuel into the fuel tank NOTE _ Use of fuel stabilizer and conditioner elimi nates the need to drain the fuel system Con sult a Yamaha dealer if the fuel system needs to be drained instead _ 3 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 ...

Page 152: ...ry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE _ Make any necessary repairs before storing the vehicle _ EE book Page 4 Wednesday August 2 2006 5 10 PM ...

Page 153: ...2 2 in Wheelbase 1 910 mm 75 2 in Ground clearance 280 mm 11 0 in Minimum turning radius 3 900 mm 154 in Basic weight With oil and full fuel tank 501 0 kg 1 105 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 EE book Page 1 Wednesday August 2 2006 5 10 PM ...

Page 154: ...antity Without oil filter cartridge replacement 2 50 L 2 20 Imp qt 2 64 US qt Model YXR45FW CAUTION In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher EE book Page 2 Wednes...

Page 155: ...8 Imp qt 0 34 US qt Radiator capacity including all routes 2 70 L 2 38 Imp qt 2 85 US qt Air filter Engine Wet element Intake duct Dry element Fuel Type Unleaded gasoline only Fuel tank capacity 30 0 L 6 60 lmp gal 7 93 US gal Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Spark plug Type manufacturer DR8EA NGK Model YXR45FW EE book Page 3 Wednesday August 2 2006 5 10 PM ...

Page 156: ...ansmission type V belt automatic Operation Right hand operation Reverse gear 30 15 2 000 Sub transmission ratio low 43 18 2 389 high 39 22 1 773 Chassis Frame type Steel tube frame Caster angle 5 0 Trail 26 0 mm 1 02 in Tire Type Tubeless Size front 25 8 12NHS rear 25 10 12NHS Model YXR45FW EE book Page 4 Wednesday August 2 2006 5 10 PM ...

Page 157: ...e Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 185 mm 7 3 in Rear wheel travel 185 mm 7 3 in Electrical Ignition system DC CDI Generator system AC magneto Battery type U1L 11 Model YXR45FW EE book Page 5 Wednesday August 2 2006 5 10 PM ...

Page 158: ...7 W 1 LED special edition models Parking brake indicator light 12 V 1 7 W 1 LED special edition models On Command four wheel drive indicator light except special edition models 12 V 1 7 W 1 On Command four wheel drive differential gear lock indicator special edition models LCD On Command differential gear lock indicator light except special edition models 12 V 1 7 W 1 On Command differential gear ...

Page 159: ...ight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Four wheel drive motor fuse 3 0 A Carburetor warmer fuse 10 0 A Signaling system fuse 10 0 A Backup fuse 10 0 A Model YXR45FW EE book Page 7 Wednesday August 2 2006 5 10 PM ...

Page 160: ...pose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Mu...

Page 161: ...s a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 200 750 75 6 2 400 1 500 150 12 4 800 3 000 300 18 7 200 4 500 450 24 9 600 6 000 600 30 12 000 7 500 750 36 14 400 9 000 900 42 16 800 10 500 1 050 48 19 200 12 000 1 200 ...

Page 162: ... THE PERIOD OF WARRANTY any authorized Yamaha Side Side Vehicle dealer will free of charge repair or replace at Yamaha s option any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corporation U S...

Page 163: ...1 2 3 4 5 6 7 8 9 10 11 12 13 EVU01090 YAMAHA EXTENDED SERVICE Y E S EE book Page 1 Wednesday August 2 2006 5 10 PM ...

Page 164: ...EE book Page 2 Wednesday August 2 2006 5 10 PM ...

Page 165: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

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