Yamaha WOLVERINE 450 Owner'S Manual Download Page 128

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8-43

●

Before adjusting the brake lever free play and
checking the brake pedal position, check the
rear brake pads for wear.

Adjusting the brake lever free play

The brake lever free play should measure 0.5–2.0
mm (0.02–0.08 in) as shown. If the free play is in-
correct, adjust it as follows.

1. Loosen the locknut.
2. Turn the brake lever free play adjusting bolt in

direction (a) to increase the free play, and in
direction (b) to decrease it.

3. Tighten the locknut.

If the correct free play cannot be obtained, have a
Yamaha dealer adjust it.

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.

1. Brake lever free play

1. Locknut
2. Brake lever free play adjusting bolt

U3C212E0.book Page 43 Tuesday, June 26, 2007 4:30 PM

Summary of Contents for WOLVERINE 450

Page 1: ...3C2 F8199 12 LIT 11626 21 47 READ THIS MANUAL CAREFULLY It contains important safety information This ATV should not be ridden by anyone under 16 years of age WARNING YFM45FXX OWNER S MANUAL DIC183 ...

Page 2: ...EBU17091 U3C212E0 book Page 1 Tuesday June 26 2007 4 30 PM ...

Page 3: ...about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INST...

Page 4: ... change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage to the ATV A NOTE provides key information to make procedures easier or...

Page 5: ...nd spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17401 AFFIX DEALER LABEL HERE YFM45FXX OWNER S MANUAL 2007 by Yamaha Motor Corporation U S A 1st edition June 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expre...

Page 6: ... 4 1 Main switch 4 1 Speed limiter 4 7 Front brake lever 4 8 Brake pedal and rear brake lever 4 9 Drive select lever 4 9 Fuel tank cap 4 10 Fuel 4 10 Fuel cock 4 12 Starter choke 4 13 Seat 4 14 Storage compartment 4 15 Adjusting the front shock absorber assemblies 4 16 Adjusting the rear shock absorber assembly 4 17 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 4 Engine oil 5 4 Fina...

Page 7: ...NG A SLOPE 7 25 WHAT TO DO 7 32 PERIODIC MAINTENANCE AND MINOR REPAIR 8 1 Owner s manual and tool kit 8 1 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing cowlings and panels 8 9 Checking the spark plug 8 15 Engine oil and oil filter cartridge 8 17 Final gear oil 8 22 Changing the differential gear oil 8 24 Coolant...

Page 8: ...cating the brake pedal 8 47 Checking the wheel hub bearings 8 47 Lubricating the steering shaft 8 47 Battery 8 47 Replacing a fuse 8 50 Replacing a headlight bulb 8 51 Adjusting a headlight beam 8 53 Replacing the tail brake light bulb 8 54 Removing a wheel 8 55 Installing a wheel 8 55 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise regulation 11 3 Maint...

Page 9: ...truc tor Contact an authorized ATV dealer or call 1 Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Never operate an...

Page 10: ... steep for the Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as...

Page 11: ...of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have Always 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 pr...

Page 12: ... open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the ATV in another vehi cle be sure it is kept upright and that the fuel cock is in the OFF position Other wise fuel may leak out of the carburetor or fuel tank HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some gas oline i...

Page 13: ...st 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 ad equate ventilation U3C212E0 book Page 5 Tuesday June 26 2007 4 30 PM ...

Page 14: ...2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U3C212E0 book Page 1 Tuesday June 26 2007 4 30 PM ...

Page 15: ...These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer U3C212E0 book Page 2 Tuesday June 26 2007 4 30 PM ...

Page 16: ...2 U3C212E0 book Page 3 Tuesday June 26 2007 4 30 PM ...

Page 17: ...filter case 4 Fuses 5 Storage compartment and tool kit 6 Seat lock lever 7 Rear shock absorber assembly spring preload adjusting 1 Spark arrester 2 Tail brake light 3 Battery 4 Spark plug 5 Rear brake fluid reservoir 6 Radiator cap 7 Front shock absorber assembly spring preload adjusting ring U3C212E0 book Page 1 Tuesday June 26 2007 4 30 PM ...

Page 18: ...he figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Starter choke 4 Drive select lever 5 Main switch 6 Speedometer unit 7 Fuel tank cap 8 Front brake fluid reservoir 9 On Command four wheel drive switch 10 Front brake lever U3C212E0 book Page 2 Tuesday June 26 2007 4 30 PM ...

Page 19: ... switch The positions of the main switch are as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U3C212E0 book Page 1 Tuesday June 26 2007 4 30 PM ...

Page 20: ... position EBU26700 Coolant temperature warning light This warning light comes on when the engine over heats When this occurs during operation stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on and then go off have a Yamaha dealer check...

Page 21: ...nism in the differ ential gear case the indicator may not come on un til the ATV starts moving EBU17970 Park indicator light This indicator light comes on when the transmis sion is in the park position EBU26362 Speedometer unit The speedometer unit is equipped with the follow ing a speedometer which shows the riding speed an odometer which shows the total distance traveled a tripmeter which shows ...

Page 22: ...of fuel This information will enable you to plan future fuel stops NOTE Pushing in the SELECT button then turning the key to ON and keeping them in this position for at least two seconds switches the display between mph and km h EBU18061 Handlebar switches EBU18080 Engine stop switch Set this switch to before starting the engine The engine stop switch controls the ignition and stops the engine whe...

Page 23: ...properly If this should happen remove the battery and recharge it EBU28210 On Command four wheel drive switch 2WD 4WD This ATV is equipped with a switch to change from two wheel drive to four wheel drive and vice versa Select the appropriate drive according to the ter rain and the conditions 2WD two wheel drive Power is supplied to the rear wheels 4WD four wheel drive Power is supplied to the rear...

Page 24: ...o four wheel drive or from four wheel drive to two wheel drive while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in two wheel drive than in four wheel drive in some cir cumstances Changing from two wheel drive to four wheel drive or from four wheel drive to two wheel drive while moving may cause the ATV to unexpectedly handle differently This could distract the operator and in cr...

Page 25: ...vail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in direction b 1 Throttle lever POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate mak HOW TO AVOID THE HAZARD Check the operation of the throttle lever be fore you st...

Page 26: ...ing screw 3 No more than 12 mm 0 47 in POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Im HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjusted to 3 0 5 0 mm 0 12 0 20 in See page 8 38 1 Front brake lever U3C212E0 book Page 8 Tuesday Jun...

Page 27: ...e brake pedal or pull the brake lever toward the handlebar grip EBU18621 Drive select lever The drive select lever is used to shift your ATV into the forward neutral reverse and park positions See the Operating the drive select lever and driv ing in reverse section on page 6 3 for the drive se lect lever operation 1 Brake pedal 1 Rear brake lever U3C212E0 book Page 9 Tuesday June 26 2007 4 30 PM ...

Page 28: ...ap by turning it counter clockwise EBU18730 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Drive select lever 1 Fuel tank cap U3C212E0 book Page 10 Tuesday June 26 2007 4 30 PM ...

Page 29: ...nleaded fuel Unleaded fuel will give you long er spark plug life and reduced maintenance cost Gasohol There are two types of gasohol gasohol contain ing ethanol and that containing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ATV performance prob...

Page 30: ...n cause a fire and se vere 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 ex haust pipe Wipe up any spilled fuel immedi ately Be sure the fuel tank cap is closed securely Do not refuel right after the engine ...

Page 31: ...h the fuel cock lever in this position the fuel reserve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke 1 Arrow mark positioned over ON 1 Arrow mark positioned over RES U3C212E0 book Page 13 Tuesday June 26 2007 4 30 PM ...

Page 32: ...tarter choke See the Starting a cold engine section on page 6 1 for proper operation EBU26981 Seat To remove the seat Push the seat lock lever backward and pull up the seat at the rear 1 Starter choke 1 Seat U3C212E0 book Page 14 Tuesday June 26 2007 4 30 PM ...

Page 33: ...in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage compartment CAUTION ECB00130 Do not store metal or sharply edged objects like tools in the storage compartment If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartment 1 Slot 2 Pro...

Page 34: ... EBU18980 Adjusting the front shock absorber as Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Storage compartment drain plug 1 Spring preload adjusting ring 2 Position indica...

Page 35: ...thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 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 absorber assem blies on the left and right s...

Page 36: ...ed at a Yamaha dealer to make this adjustment EWB00010 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 U3C212E0 book Page 18 Tuesday June 26 2007 4 30 PM ...

Page 37: ...ne which service should be performed by a Yamaha dealer POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedur...

Page 38: ...and add recommended brake fluid to specified level if necessary Check hydraulic system for leakage Correct if necessary 5 5 8 39 8 40 8 42 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check lever free play and adjust if necessary Check brake pads for wear and replace if necessary Check brake fluid level in reservoir and add recommended brake fluid to spec...

Page 39: ...6 Axle boots Check for cracks or damage and replace if necessary 8 44 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 9 Instruments lights and switches Check operation and correct if necessary 5 9 ITEM ROUTINE PAGE U3C212E0 book Page 3 Tuesday June 26 2007 4 30 PM ...

Page 40: ...st be checked on a cold en gine since the level varies with engine tempera ture WARNING EWB00490 POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere 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 carefu...

Page 41: ...he pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If a lever moves slow ly inward there may be a leak in the brake system If there is any leakage the brake system should be checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the ...

Page 42: ... the brakes If a problem cannot be corrected by the adjustment procedures pro vided in this manual have a Yamaha dealer check for the cause POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or opera tion of this ATV with improper or uneven tire pressure may cause loss of control in creasing your risk o...

Page 43: ...s must be equal on both sides Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 37 0 kPa 5 3 psi 0 370 kgf cm Rear 37 0 kPa 5 3 psi 0 370 kgf cm Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm Rear 250 kPa 36 psi 2 5 kg...

Page 44: ...he tire pressures to the following specifications EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm 0 12 in 1 Low pressure tire gauge Recommended pressure Front 40 0 kPa 5 8 psi 0 400 kgf cm Rear 40 0 kPa 5 8 psi 0 400 kgf cm Minimum Front 37 0 kPa 5 3 psi 0 370 kgf cm Rear 37 0 kPa 5 3 psi 0 370 kgf cm Maximum Front 43 0 kPa 6 2 psi 0 430 kgf cm Rear 43 0 kPa 6 2 ps...

Page 45: ...ll nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary 1 Tire wear limit U3C212E0 book Page 9 Tuesday June 26 2007 4 30 PM ...

Page 46: ...g familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an acci dent 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 POTENTIAL HAZARD Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO...

Page 47: ... mended to shift into the neutral or park position before starting the engine 4 Use the starter choke in reference to the fig ure Position 1 Cold engine start with ambient temperature below 5 C 40 F Position 2 Cold engine start with ambient temperature Ambient temp starter choke position 5 Apply the rear brake lever 6 Completely close the throttle lever and start the engine by pushing the start sw...

Page 48: ... the starter choke to position 3 before riding NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EBU20291 Starting a warm engine Follow the same procedure as for starting a cold EBU20450 Operating the drive select lever and driving in reverse CAUTION ECB00170 Before shifting stop the ATV otherwise the transmission may be damaged Shifting Neutral to...

Page 49: ...utral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide NOTE When in reverse the reverse indicator light 1 Drive select lever 2 F Forward 3 N Neutral 4 R Reverse 5 P Park 1 Drive select lever 2 F Forward 3 N Neutral 4 R Reverse 5 P Park U3C212E0 book Page 4 Tuesday June 26 2007 4 30 PM ...

Page 50: ...i or 20 hours The various parts in the engine wear and polish themselves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided 0 160 km 0 100 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 160...

Page 51: ... pedal applied shift the drive select lever to the park position POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing 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 ATV transversely across the incline stop the en gine shift the drive select lever to the p...

Page 52: ...ding could affect your ability to control the ATV Do not mount an accessory where it could inter could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU26380 Loading As originally equipped this ATV is not desi...

Page 53: ...should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING EWB00750 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death POTENTIAL HAZARD Overloading this ATV or carrying or ...

Page 54: ...7 EBU21131 RIDING YOUR ATV U3C212E0 book Page 1 Tuesday June 26 2007 4 30 PM ...

Page 55: ...skills acquired through practice Take your time to fully learn techniques before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable ac tivity 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 Manu...

Page 56: ...for children under 16 years of age WARNING EWB00901 POTENTIAL HAZARD Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training co...

Page 57: ...D A child under 16 should never operate an ATV with engine size greater than 90 cc WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as need ed during operation It is not for carrying passengers U...

Page 58: ...d motorcycle helmet increases your chances of a severe head injury or death in the event of an acci dent Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases your chances of severe injury in the event of an accident U3C212E0 book Page 5 Tuesday June 26 2007 4 30 PM ...

Page 59: ...n 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 1 Protective clothing 2 Goggles U3C212E0 book Page 6 Tuesday June 26 2007 4 30 PM ...

Page 60: ...r drugs WHAT CAN HAPPEN Could seriously affect your judgment HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make...

Page 61: ...s of control in creasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this ATV on page 5 6 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 7 POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of ...

Page 62: ...es As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add ac cessories so that you can carry cargo or tow a trail er you must use common sense and good judgment Use extra caution when riding the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Re duce your speed when adding additional loads WARNING EW...

Page 63: ...uld be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer U3C212E0 book Page 10 Tuesday June 26 2007 4 30 PM ...

Page 64: ...ce 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 foot board your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation POTENTIAL HAZARD Attempting whe...

Page 65: ...ch in some situations could HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nents designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer U3C212E0 book Page 12 Tuesday June ...

Page 66: ...em WHAT CAN HAPPEN Dry grass or brush or other combustible ma terial accumulated around the engine area could catch fire Someone touching the exhaust system dur ing 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 exhau...

Page 67: ...eways parking lots and streets POTENTIAL HAZARD 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 U3C212E0 book Page 14 Tuesday June 26 2007 4 30 PM ...

Page 68: ... terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV POTENTIAL HAZARD Failure to use extra care when operating on excessively roug...

Page 69: ...p pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain 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 in jured U3C212E0 book Page 16 Tuesday June 26 2007 4 30 PM ...

Page 70: ...ter choke to the closed position and shift the drive select lever into the forward position Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is ap plied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds until you are thoroughly famil iar with the operation of...

Page 71: ...ay continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippery or loose it may help to position more of your weight over the POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a colli sion or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in th...

Page 72: ...tle slopes Try more difficult climbs only after you have devel oped your skill In all cases avoid inclines with slip pery or loose surfaces or obstacles that might cause you to lose control WARNING EWB01090 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steeper inclines standing on the footboar...

Page 73: ...tart up any hill Never climb hills with excessively slippery 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 U3C212E0 book Page 20 Tuesday June 26 2007 4 30 PM ...

Page 74: ... 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 tech nique as described in the Owner s Manual on level ground Be very careful when turn ing on any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of...

Page 75: ...IAL HAZARD Stalling rolling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill If you begin rolling backwards Keep weight uphill 2WD Never apply the rear brake while roll ing backwards Apply the front brake When fully stopped ...

Page 76: ...sing either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sud den application of either the front or rear brake be cause the wheels on the uphill side could come off the ground Apply both the front and rear brakes Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride ...

Page 77: ...7 U3C212E0 book Page 24 Tuesday June 26 2007 4 30 PM ...

Page 78: ...our ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING EWB01141 POTENTIAL HAZARD Improperly crossing hills or turning on hills HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique a...

Page 79: ...7 U3C212E0 book Page 26 Tuesday June 26 2007 4 30 PM ...

Page 80: ...150 Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability 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 acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in wa...

Page 81: ...ir filter case the V belt cooling duct check hose the drive select lever box check hose and the storage compartment drain plugs Also remove the V belt case drain plug to drain any water that may have accumu lated Wash the ATV in fresh water if it has been 1 Air filter case check hose U3C212E0 book Page 28 Tuesday June 26 2007 4 30 PM ...

Page 82: ... damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult EWB01160 1 Drive select lever box check hose 1 V belt case drain plug U3C212E0 book Page 29 Tuesday June 26 2007 4 30 PM ...

Page 83: ...ns positioning your weight over the front wheels will sometimes help WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for ob stacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner ...

Page 84: ...re WARNING EWB01170 WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding tech niques completely 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 sliding by prac...

Page 85: ... forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance ...

Page 86: ... DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01820 EBU21720 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and always carry it on the bottom of the seat as shown Put the owner s tool kit and low pres sure tire gauge under the seat POTENTIAL HAZARD Servicing an engine whil...

Page 87: ...rating this ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nent...

Page 88: ...should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if n...

Page 89: ...s and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U3C212E0 book Page 4 Tuesday June 26 2007 4 30 PM ...

Page 90: ...ect if necessary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake lever free play and adjust if neces sary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 4 Brake hoses Check for cracks or other damage...

Page 91: ...sed grease 13 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 14 Engine mount Check for cracks or other damage and replace if necessary 15 Axle boots Check for cracks or other damage and replace if necessary 16 Engine oil Change Check ATV for oil leakage and correct if neces sary 17 Engine oil filter car tridge Replace NO ITEM CHECK OR MAINTENA...

Page 92: ...rottle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 25 Front and rear brake switches Check operation and correct if necessary 26 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes fir...

Page 93: ...rrect the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U3C212E0 book Page 8 Tuesday June 26 2007 4 30 PM ...

Page 94: ... The cowlings and panels shown need to be re moved to perform some of the maintenance jobs described in this chapter Refer to this section each time a cowling or panel needs to be removed and installed EBU26582 Cowling A To remove the cowling 1 Panel B 2 Cowling A 3 Cowling B 4 Panel C 5 Panel D U3C212E0 book Page 9 Tuesday June 26 2007 4 30 PM ...

Page 95: ...8 4 Remove cowling A by removing the bolts nuts and washers 1 Speedometer unit coupler 1 Bolt left side U3C212E0 book Page 10 Tuesday June 26 2007 4 30 PM ...

Page 96: ... 2 Pull the fuel tank breather hose out of the han dlebar cover 3 Pull off the handlebar cover CAUTION ECB00740 Do not disconnect the main switch coupler 4 Remove the fuel tank cap by turning it coun terclockwise CAUTION ECB00750 Make sure that no foreign material enters the fuel tank Be sure to install the fuel tank cap immedi ately after removing and installing the cowl ing U3C212E0 book Page 11...

Page 97: ...ve the fuel tank cap by turning it coun terclockwise 2 Install the cowling by installing the bolts 3 Install the fuel tank cap by turning it clockwise 4 Place the handlebar cover in the original posi tion 5 Pass the fuel tank breather hose through the 1 Bolt 1 Bolt right side U3C212E0 book Page 12 Tuesday June 26 2007 4 30 PM ...

Page 98: ...ace the panel in the original position and install the bolt ECB00380 Panel B To remove the panel Pull outward on the areas shown To install the panel Insert the projections on the panel into the slots in cowling A and push inward 1 Panel A 2 Bolt 1 Panel B U3C212E0 book Page 13 Tuesday June 26 2007 4 30 PM ...

Page 99: ...hen take the panel off To install the panel Place the panel in the original position and install the bolts Panel D To remove the panel Pull outward on the areas shown 1 Projection 2 Slot 1 Panel C 2 Bolt U3C212E0 book Page 14 Tuesday June 26 2007 4 30 PM ...

Page 100: ...ce heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 1 Panel D U3C212E0 book Page 15 Tuesday June 26 2007 4 30 PM ...

Page 101: ...deal color when the ATV is ridden normally NOTE 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spark plug wrench Specified spark plug NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in U3C212E0 book P...

Page 102: ...ened to the specified torque as soon as possible 4 Install the spark plug cap EBU26425 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the intervals spec ified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Re...

Page 103: ... level NOTE The engine oil should be between the minimum and maximum level marks 6 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level 7 Insert the dipstick into the oil filler hole and 1 Engine oil filler cap 1 Dipstick 2 Maximum level mark 3 Minimum level mark U3C212E0 book Page 18 Tuesday June 26 2007 4 30 PM ...

Page 104: ...off 4 Place an oil pan under the engine to collect the used oil 5 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase NOTE Skip steps 6 10 if the oil filter cartridge is not being replaced 6 Remove panel C See page 8 9 7 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge U3C212E0 book Page 19 Tuesday June 26 ...

Page 105: ... the O ring of the new oil filter cartridge NOTE Make sure that the O ring is properly seated 9 Install the new oil filter cartridge with an oil fil ter wrench and then tighten it to the specified torque with a torque wrench 1 Oil filter wrench 1 O ring U3C212E0 book Page 20 Tuesday June 26 2007 4 30 PM ...

Page 106: ...TION ECB00300 In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Recommended oil See page 10 1 Oil quantity Without oil filter cartridge replacement 2 30 L 2 43 US qt 2 02 I...

Page 107: ...have a Yamaha dealer check and repair the ATV In ad dition the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface 2 Remove the final gear oil filler bolt and then check the oil level in the final gear case NOTE The oil level should be at...

Page 108: ...ighten it to the specified torque 6 Add the recommended final gear oil to the brim of the filler hole as shown Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear case guard 2 Bolt 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf U3C212E0 book Page 23 Tuesday June 26 2007 4 30 PM ...

Page 109: ...d for oil leakage before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In addition the differential gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Final gear oil 2 Final gear oil filler bolt 3 Correct oil level Recommended final gear oil See page 10 1 Tightening torque Final gear oil filler bolt 2...

Page 110: ...e 4 Install the drain bolt and then tighten it to the specified torque 5 Add the specified amount of the recommend ed differential gear oil 1 Differential gear oil filler bolt 1 Differential gear oil drain bolt Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf U3C212E0 book Page 25 Tuesday June 26 2007 4 30 PM ...

Page 111: ...In addition the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart EBU27940 To check the coolant level 1 Place the ATV on a level surface NOTE The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser voir NOTE The coolant should be between the minimum and maxi...

Page 112: ...oir cap CAUTION ECB00401 If coolant is not available use distilled water or soft tap water instead Do not use hard wa ter or salt water since it is harmful to the en 1 Maximum level mark 2 Minimum level mark 1 Coolant reservoir cap Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt U3C212E0 book Page 27 Tuesday June 26 2007 4 30 PM ...

Page 113: ...e ATV on a level surface 2 Remove panels C and D See page 8 9 3 Place a container under the engine and then remove the coolant drain bolt Use a trough or a similar object as shown to prevent coolant from spilling on the footrest POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam HOW TO AVOID THE HAZARD Wa...

Page 114: ...then drain the coolant from the cool ant reservoir 8 After draining the coolant thoroughly flush the cooling system with clean tap water 9 Replace the coolant drain bolt washer if it is damaged install the coolant drain bolt and then tighten it to the specified torque 1 Trough 1 Coolant reservoir hose U3C212E0 book Page 29 Tuesday June 26 2007 4 30 PM ...

Page 115: ...ll the radiator cap start the engine let it idle for several minutes and then turn it off 14 Remove the radiator cap to check the coolant level in the radiator If it is low add sufficient coolant until it reaches the top of the radiator and then install the radiator cap 15 Start the engine and then check for coolant leakage NOTE If any leakage is found have a Yamaha dealer check the cooling system...

Page 116: ...in unusually wet or dusty areas 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 fil ter case 2 Remove the air filter case cover by unhooking the holders 3 Pull the air filter element out of the air filter case 1 Air filter case cover holder 2 Air filter case cover U3C212E0 book Page 31 Tu...

Page 117: ...e material from the air filter element frame 5 Wash the sponge material gently but thor oughly in solvent 1 Air filter element 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate U3C212E0 book Page 32 Tuesday June 26 2007 4 30 PM ...

Page 118: ...ial NOTE The sponge material should be wet but not drip ping 9 Pull the sponge material over the air filter ele ment frame and then install the lock plate 10 Insert the air filter element into the air filter POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD ...

Page 119: ...ION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the air filter element will affect carburetor jetting with subsequent EBU26451 Cleaning the spark arrester B...

Page 120: ...2 Spark arrester Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf 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 poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching...

Page 121: ...e carburetor The carburetor should be checked and if neces sary adjusted at the intervals specified in the peri odic maintenance and lubrication chart The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment 1 V belt...

Page 122: ...cified in the periodic maintenance and lubrica tion chart NOTE A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it up NOTE The engine is warm when it quickly responds to the throttle crease the engine idling speed turn the throt tle stop screw in direction a and to decrease it turn the screw in direction b NOTE If the specified idling speed cannot be obtained a...

Page 123: ...d ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle cable free play turn the adjusting bolt in direction b 3 Tighten the locknut EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To...

Page 124: ... intervals specified in the periodic main tenance and lubrication chart EBU24171 Front brake pads Check each front brake pad for damage and mea sure the lining thickness If a brake pad is dam aged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set NOTE The wheels need to be removed to check the brake pads See page 8 55 EBU26460 Rear brake pa...

Page 125: ...id may allow air to enter the brake system possibly causing it to become inef fective brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Front brake 1 Wear indicator groove 1 Minimum level mark U3C212E0 book Page 40 Tuesday June 26 2007 4 30 PM ...

Page 126: ...e boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid imme diately As the brake pads wear it is normal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24290 Changing the brake fluid Have a Yamaha dealer change the...

Page 127: ...djusted and brake pedal position must be checked and if nec essary adjusted at the intervals specified in the periodic maintenance and lubrication chart NOTE 1 Brake lever free play 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...

Page 128: ...wn If the free play is in correct adjust it as follows 1 Loosen the locknut 3 Tighten the locknut If the correct free play cannot be obtained have a Yamaha dealer adjust it 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 1 Brake lever free play 1 Locknut 2 Brake lever free play adjusting bolt U3C212E0 book Page 43 Tu...

Page 129: ... Check the axle boots for tears or damage If any damage is found have them re placed by a Yamaha dealer 1 Brake pedal position POTENTIAL HAZARD Operating with improperly serviced or ad 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 brak...

Page 130: ... should be adjusted by a Yamaha dealer 1 Remove panel A See page 8 9 NOTE The brake light switch is properly adjusted when the brake light comes on just before braking takes effect 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direc tion a To make the brake light come on lat er turn the adjusting nut in dire...

Page 131: ...evers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary Recommended lubricant Engine oil POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cables can also be come frayed or kinked which could restrict the operation of controls and lead to an ...

Page 132: ...ication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU25102 Lubricating the steering shaft The steering shaft must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart EBU25212 Battery This model is equipped with a sealed type MF battery which does not require any maintenance ...

Page 133: ...ed You could be se verely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gas es HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get...

Page 134: ...e battery leads to the battery terminals CAUTION ECB00630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a spe cial constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a constant voltage battery charg er have a Yamaha dealer charge ...

Page 135: ...s 1 Turn the key to OFF and turn off all electrical 1 Main fuse 2 Spare main fuse 3 Fuse box 1 Headlight fuse 2 Ignition fuse 3 Auxiliary DC jack fuse for optional auxiliary DC jack 4 Four wheel drive motor fuse 5 Signaling system fuse 6 Backup fuse for odometer and tripmeter 7 Spare fuse U3C212E0 book Page 50 Tuesday June 26 2007 4 30 PM ...

Page 136: ...f a headlight bulb burns out replace it as follows 1 Remove the headlight bulb holder cover at the rear of the headlight by pulling it off Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Four wheel drive motor fuse 3 0 A Signaling system fuse 10 0 A Auxiliary DC jack fuse 10 0 A Backup fuse POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cau...

Page 137: ...t by aligning the projection on the bulb with the groove in the headlight unit 1 Headlight bulb holder cover POTENTIAL HAZARD A headlight bulb is hot when it is on and im mediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it U3C212E0 book Page ...

Page 138: ...finger prints on the headlight bulb using a cloth moistened with alcohol or thinner 6 Install the headlight bulb holder cover at the rear of the headlight CAUTION ECB00670 Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 7 Adjust the headlight beam if necessary EBU25560 Adjusting a headlight beam 1 Do not touch the glass part of the bulb U3C212E...

Page 139: ...rection b EBU25600 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counterclockwise 1 Headlight beam adjusting bolt 1 Screw U3C212E0 book Page 54 Tuesday June 26 2007 4 30 PM ...

Page 140: ...lens may break EBU25650 Removing a wheel 1 Loosen the wheel nuts 4 Remove the wheel EBU25700 Installing a wheel 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 nuts with their tapered side to wards the wheel U3C212E0 book Page 55 Tuesday June 26 2007 4 30 PM ...

Page 141: ...ick and easy procedures for checking these vital systems yourself However should your ATV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to e...

Page 142: ...N HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces U3C212E0 book Page 57 Tuesday June 26 2007 4 30 PM ...

Page 143: ...tarter 2 Compression There is compression There is no compression Check the ignition Have a Yamaha dealer check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Check the battery 4 Battery Dry Wet Open the throttle halfway and operate the ...

Page 144: ...he cap Allow any remaining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See NOTE Start the engine If the engine overheats again have a Yamaha dealer ...

Page 145: ...ECB00710 Excessive water pressure may cause water ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places 5 Rinse the ATV off immediately with clean wa ter and dry all surfac...

Page 146: ...rain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping abil ity increasing the chance of an...

Page 147: ...d the spark plug cap 6 Lubricate all control cables and the pivoting points of all levers and pedals 7 Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to sively ...

Page 148: ...il and fuel 250 0 kg 551 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Compression ratio 10 00 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 YAMALUBE 4 CW 5W30 or SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 2...

Page 149: ...mp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 14 5 L 3 83 US gal 3 19 Imp gal Fuel reserve amount Type x quantity BSR33 x 1 Spark plug s Manufacturer model NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Shaft driv...

Page 150: ...ssure measured on cold tires Recommended Front 40 0 kPa 5 8 psi 0 400 kgf cm Rear 40 0 kPa 5 8 psi 0 400 kgf cm Maximum Front 43 0 kPa 6 2 psi 0 430 kgf cm Rear 43 0 kPa 6 2 psi 0 430 kgf cm Front wheel Wheel type Panel wheel Rim size 12 x 6 0AT Rear wheel Wheel type Panel wheel Rim size 12 x 7 5AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake T...

Page 151: ...o Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Headlight Bulb type Tail brake light 12 V 5 0 21 0 W 1 Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Park indicator light LED On Command four wheel drive indicator LCD Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Bac...

Page 152: ...ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number is stamped into 1 Key identific...

Page 153: ...50 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need 1 Vehicle identification number front left side 1 Model label U3C212E0 book Page 2 Tuesday June 26 2007 4 30 PM ...

Page 154: ...se of noise control prior to its sale or delivery to the ul timate 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 Muf...

Page 155: ...he 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 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 U3C21...

Page 156: ...equent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also warr...

Page 157: ... set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha ATV dealer within the co...

Page 158: ...o pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging...

Page 159: ... expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 U3C212E0 book Page 8 Tuesday June 26 2007 4 30...

Page 160: ...11 EBU26132 U3C212E0 book Page 9 Tuesday June 26 2007 4 30 PM ...

Page 161: ...nt and rear 5 5 C Cables checking and lubricating 8 46 Carburetor adjusting 8 36 Chassis fasteners 5 9 Cleaning 9 1 Differential gear oil changing 8 24 Drive select lever 4 9 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 39 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 37 Engine oil 5 4 Engine oil and oil filter cartridge 8 17 ...

Page 162: ...ndicator light 4 2 Riding your ATV 7 1 Spark arrester cleaning 8 34 Spark plug checking 8 15 Specifications 10 1 Speed limiter 4 7 Speedometer unit 4 3 Starter choke 4 13 Start switch 4 5 Steering shaft lubricating 8 47 Storage 9 2 Storage compartment 4 15 T Tail brake light bulb replacing 8 54 Throttle cable free play adjusting 8 38 Throttle lever 4 6 5 6 Tire pressure measuring 5 7 Tires 5 6 Tir...

Page 163: ...U3C212E0 book Page 3 Tuesday June 26 2007 4 30 PM ...

Page 164: ...ment 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 PROTECTI...

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Yamaha WOLVERINE 450, Owner'S Manual

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