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Yamaha WOLVERINE YFM35XW, Owner'S Manual

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Yamaha WOLVERINE YFM35XW Owner'S Manual Download Page 90

8-9

8

EBU23210

Checking the spark plug 

The spark plug is an important engine component,
which is easy to check. Since 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.

2. Remove the spark plug as shown, with the

spark plug wrench included in the owner’s tool
kit.

To check the spark plug

1. Check that the porcelain insulator around the

center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).

NOTE:

If the spark plug shows a distinctly different color,
the engine could be defective. Do not attempt to di-
agnose such problems yourself. Instead, have a
Yamaha dealer check the ATV.

1. Spark plug cap

1. Spark plug wrench

U3D510E0.book  Page 9  Friday, December 2, 2005  1:07 PM

Summary of Contents for WOLVERINE YFM35XW

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

Page 2: ...EBU17091 U3D510E0 book Page 1 Friday December 2 2005 1 07 PM ...

Page 3: ...out 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 INSTRU...

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: ... 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 YFM35XV OWNER S MANUAL 2005 by Yamaha Motor Corporation U S A 1st edition November 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expr...

Page 6: ... Main switch 4 1 Front brake lever 4 5 Brake pedal and rear brake lever 4 6 Parking brake 4 7 Drive select lever 4 7 Fuel tank cap 4 8 Fuel 4 8 Fuel cock 4 10 Starter choke 4 11 Seat 4 12 Storage compartment 4 13 Adjusting the front shock absorber assemblies 4 14 Adjusting the rear shock absorber assembly 4 15 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final gear...

Page 7: ...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 the panel 8 8 Checking the spark plug 8 9 Engine oil and oil filter cartridge 8 11 Final gear oil 8 15 Cleaning the air filter element 8 17 Cleaning the spark arrester 8 21 V belt cooling duct check hose 8 22 V bel...

Page 8: ...s 8 34 Lubricating the knuckle shafts 8 34 Lubricating the steering shaft 8 34 Battery 8 34 Replacing a fuse 8 36 Replacing a headlight bulb 8 38 Adjusting a headlight beam 8 39 Replacing the tail brake light bulb 8 40 Removing a wheel 8 41 Installing a wheel 8 41 Troubleshooting 8 43 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise regulation 11 3 Maintenance record...

Page 9: ...orized ATV dealer or call 1 800 887 2887 to find out about the training 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 stre...

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: ...f 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 pre...

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 in...

Page 13: ...t 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 U3D510E0 book Page 5 Friday December 2 2005 1 07 PM ...

Page 14: ...2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U3D510E0 book Page 1 Friday December 2 2005 1 07 PM ...

Page 15: ...hese 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 U3D510E0 book Page 2 Friday December 2 2005 1 07 PM ...

Page 16: ...2 U3D510E0 book Page 3 Friday December 2 2005 1 07 PM ...

Page 17: ... cock 3 Air 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 Spark plug 4 Front shock absorber assembly spring preload adjusting ring 5 Brake pedal 6 V belt case U3D510E0 book Page 1 Friday December 2 2005 1 07 PM ...

Page 18: ...and instruments NOTE 1 Rear brake lever 2 Left handlebar switches 3 Starter choke 4 Drive select lever 5 Main switch 6 Fuel tank cap 7 Front brake lever 8 Throttle lever U3D510E0 book Page 2 Friday December 2 2005 1 07 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 U3D510E0 book Page 1 Friday December 2 2005 1 07 PM ...

Page 20: ... with the engine stop switch set to and then pushing the start switch If the warning light does not come on while the start switch is being pushed then go off after the start switch is released have a Yamaha dealer check the electrical circuit If the warning light stays on allow the engine to cool If the warning light stays on when the engine is cool have a Yamaha dealer check the electrical circu...

Page 21: ...prior to starting the engine EBU18151 Light switch OFF Set this switch to to turn on the low beams and the taillight Set the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights CAUTION ECB00040 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to the point that the starter moto...

Page 22: ...ivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is 1 Throttle lever POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate mak ing it difficult to speed up or slow down when you need to This could cause an acci dent HOW TO AVOID THE HAZARD Check the operation of the throttle lever b...

Page 23: ...ar grip 1 Locknut 2 Adjusting screw 3 No more than 12 mm 0 47 in POTENTIAL HAZARD Improper adjustment of the speed limiter WHAT CAN HAPPEN The throttle cable could be damaged Im proper throttle operation could result You could lose control have an accident or be in jured 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 pla...

Page 24: ...n the right side of the ATV and the rear brake lever is located on the left handlebar To apply the rear brake push down on the brake pedal or pull the brake lever toward the handlebar grip 1 Front brake lever 1 Brake pedal U3D510E0 book Page 6 Friday December 2 2005 1 07 PM ...

Page 25: ...ion on page 6 3 for the drive select lever operation 1 Parking brake lock plate POTENTIAL HAZARD WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start ing the engine This could cause loss of con trol or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause ...

Page 26: ...p 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 U3D510E0 book Page 8 Friday December 2 2005 1 07 PM ...

Page 27: ...leaded 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 probl...

Page 28: ... 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 h...

Page 29: ... 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 U3D510E0 book Page 11 Friday December 2 2005 1 07 PM ...

Page 30: ...arter 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 U3D510E0 book Page 12 Friday December 2 2005 1 07 PM ...

Page 31: ...n 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 Proj...

Page 32: ...s EBU18980 Adjusting the front shock absorber 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 indicato...

Page 33: ...ereby 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 sid...

Page 34: ...d 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 U3D510E0 book Page 16 Friday December 2 2005 1 07 PM ...

Page 35: ...ces sary Check fuel line for leakage Correct if necessary 4 8 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 11 Final gear oil Check ATV for oil leakage Correct if necessary 5 3 8 15 Front brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check brake pads for wea...

Page 36: ...Lubricate pedal pivoting point if necessary 8 33 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 32 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 8 Instruments lights and switches Check operation and correct if necessary 5 8 POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain ...

Page 37: ...hich 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 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 ...

Page 38: ...lever moves slowly 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 brake pads and shoes for wear See page 8 25 WARNING EWB00540 Recommended brake fluid D...

Page 39: ...9760 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Correct if necessary U3D510E0 book Page 5 Friday December 2 2005 1 07 PM ...

Page 40: ...ow have been approved by Yamaha Motor Manufacturing Corpora tion of America for this model Other tire combinations are not recommended Front Manufacturer model MAXXIS M937 Size AT23 x 8 12 Rear Manufacturer model MAXXIS M938 Size AT23 x 10 12 Type Tubeless The tires should be set to the recommend ed pressure Recommended tire pressure Front 25 kPa 3 6 psi 0 25 kgf cm Rear 25 kPa 3 6 psi 0 25 kgf cm...

Page 41: ... specifications Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 22 kPa 3 2 psi 0 22 kgf cm Rear 22 kPa 3 2 psi 0 22 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 kgf cm Higher pressure...

Page 42: ...ghts and switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 25 kPa 3 6 psi 0 25 kgf cm Rear 25 kPa 3 6 psi 0 25 kgf cm Minimum Front 22 kPa 3 2 psi 0 22 kgf cm Rear 22 kPa 3 2 psi 0 22 kgf cm Maximum Front 28 kPa 4 1 psi 0 28 kgf cm Rear 28 kPa 4 1 psi 0 28 kgf cm 1 Tire wear limit U3D510E0 book Page 8 Friday December 2 2005...

Page 43: ...amiliar 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 AV...

Page 44: ... neutral position before starting the engine 5 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 between 0 C 30 F and 30 C 90 F Ambient temp starter choke position 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE If the engine fails t...

Page 45: ...n 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 EBU20370 Operating the drive select lever and driving in reverse CAUTION ECB00170 Before shifting stop the ATV otherwise the transmission may be damaged Shifting Forward 1...

Page 46: ...the shift NOTE When in reverse the reverse indicator light should come on If the indicator light does not come on have a Yamaha dealer check the electrical circuit 4 Check behind for people or obstacles and then release the brake pedal 1 Drive select lever 2 F Forward 3 N Neutral 4 R Reverse 1 Drive select lever 2 F Forward 3 N Neutral 4 R Reverse U3D510E0 book Page 4 Friday December 2 2005 1 07 P...

Page 47: ...ours Avoid prolonged operation above 3 4 throttle Rev the engine freely but do not use full throttle at any time 20 hours and beyond The ATV can now be operated normally CAUTION ECB00220 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the ATV EBU20700 Parking When parking the ATV stop the engine shift the drive select lever into the forwa...

Page 48: ... dealer has a variety of gen 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 shift the drive select lever to the forward position stop the engine apply the parking bra...

Page 49: ...ding 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 Never exceed the weight limits shown An over loaded ATV can be unstable If you are carrying cargo and towing a trailer in clude the tongue weight in the maximum ATV load limit Load cargo on the carriers as close to the center of the ATV a...

Page 50: ...ng this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing U3D510E0 book Page 8 Friday December 2 ...

Page 51: ...7 EBU21131 RIDING YOUR ATV U3D510E0 book Page 1 Friday December 2 2005 1 07 PM ...

Page 52: ... to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and un derstand the operation of the controls Pay partic RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to ...

Page 53: ...should then regularly practice the skills learned in the course and the operating techniques de scribed in this Owner s Manual For more in formation about the training course contact an authorized ATV dealer or call 1 800 887 2887 POTENTIAL HAZARD Failure to follow the age recommendations WHAT CAN HAPPEN Use by children of ATVs that are not recom mended for their age can lead to severe inju ry or ...

Page 54: ...APPEN 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 U3D510E0 book Page 4 Friday December 2 2005 1 07 PM ...

Page 55: ...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 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 ...

Page 56: ... 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 57: ... 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 t...

Page 58: ...s 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 EWB...

Page 59: ...ever exceed the stated load capacity for this ATV Cargo should 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 U3D510E0 book Page 9 Friday December 2 2005 1 07 PM ...

Page 60: ... 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 WHAT CAN HAPPEN Increases the chance of an accident includ ing an overturn HOW TO AVOID THE ...

Page 61: ...D 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 U3D510E0 book Page 11 Friday December 2 2005 1 07 PM ...

Page 62: ...m 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 exhaus...

Page 63: ...ways 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 U3D510E0 book Page 13 Friday December 2 2005 1 07 PM ...

Page 64: ...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 rough...

Page 65: ...n excessively rough slip 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 U3D510E0 book Page 15 Friday December 2 2005 1...

Page 66: ...e starter choke to the closed position and shift the drive select lever into the forward position then release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds un til you are thoro...

Page 67: ...y 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 thi...

Page 68: ...le 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 footboard...

Page 69: ...art 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 U3D510E0 book Page 19 Friday December 2 2005 1 07 PM ...

Page 70: ...rol 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 a hill Always follow proper procedures as de scribed in the Owner s Manual ...

Page 71: ...e WARNING EWB01261 POTENTIAL 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 Apply the brakes Apply the parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never app...

Page 72: ...efully choose your path and ride no faster than you will be able to react to ob stacles which may appear WARNING EWB01130 POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner s Man ual Note a special technique is required when bra...

Page 73: ...7 U3D510E0 book Page 23 Friday December 2 2005 1 07 PM ...

Page 74: ...ur 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 as...

Page 75: ...7 U3D510E0 book Page 25 Friday December 2 2005 1 07 PM ...

Page 76: ...50 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 wat...

Page 77: ...r 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 U3D510E0 book Page 27 Friday December 2 2005 1 07 PM ...

Page 78: ...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 U3D510E0 book Page 28 Friday December 2 2005 1 07 PM ...

Page 79: ... control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide 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...

Page 80: ...ach section on riding tech niques completely WHAT TO DO If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your 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 practic...

Page 81: ...ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 18 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 If your ATV encounters shallow water Ride slowly and carefully through slow mo...

Page 82: ...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 while...

Page 83: ...ating 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 nents...

Page 84: ...hould 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 ne...

Page 85: ... 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 U3D510E0 book Page 4 Friday December 2 2005 1 07 PM ...

Page 86: ...f 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 and pedal free play and adjust if necessary Replace brake shoes Whenever worn to the limit 4 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years 5 Wheels Check r...

Page 87: ...Knuckle shafts Lubricate with lithium soap based grease 15 Steering shaft Lubricate with lithium soap based grease 16 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 17 Engine mount Check for cracks or other damage and replace if necessary 18 Engine oil Change Check ATV for oil leakage and correct if neces sary 19 Engine oil filter car Replace ...

Page 88: ...peration 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 first month 1 3 6 6 12 km mi 320 200 1300 ...

Page 89: ...nance jobs described in this chapter Refer to this section each time the panel needs to be removed and installed Remove the bolt and then take the panel off To install the panel Place the panel in the original position and install the bolt CAUTION ECB00380 When installing the panel be sure not to pinch the cables or wires 1 Panel A 1 Panel A 2 Bolt U3D510E0 book Page 8 Friday December 2 2005 1 07 ...

Page 90: ...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 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden...

Page 91: ...specification 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in 1 Spark plug gap Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf U3D510E0 book Pag...

Page 92: ...e 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 Start the engine warm it up for several min utes and then turn it off 3 Wait a few minutes until the oil settles before checking 5 Insert the dipstick into the filler ho...

Page 93: ...he engine oil with or without oil fil ter cartridge replacement 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase 1 Dipstick 2 Maximum level mark 3 Minimum level mark 1 ...

Page 94: ...ble at a nearby Yamaha dealer 6 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge NOTE Make sure that the O ring is properly seated 7 Install the new oil filter cartridge with an oil fil 1 Oil filter cartridge 1 O ring U3D510E0 book Page 13 Friday December 2 2005 1 07 PM ...

Page 95: ...d ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt Recommended oil See page 10 1 Oil quantity Without oil filter cartridge replacement 2 2...

Page 96: ...l surface NOTE The final gear oil level must be checked on a cold engine 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 the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 4 Install the oil filler bolt and then tighten it...

Page 97: ...il filler bolt and the fi nal gear oil drain bolt to drain the oil from the final gear case 5 Install the drain bolt and then tighten it to the specified torque 6 Add the recommended final gear oil to the brim of the filler hole as shown 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 U3D510E0 book Page 16 Friday Dece...

Page 98: ...r filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas 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 23 Nm 2 3 m kgf 17 ft lbf Tightening tor...

Page 99: ...ean the air filter element and air fil ter case 1 Remove the seat See page 4 12 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 check hose 1 Air filter case holder 2 Air filter case cover U3D510E0 book Page 18 Friday December 2 2005 1 07 PM ...

Page 100: ... material gently but thor oughly in solvent WARNING EWB01900 1 Air filter element 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN U3D510E0 book Page 19 Friday December 2 2005 1 07 PM ...

Page 101: ...perated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine CAUTION ECB00460 Make sure ...

Page 102: ...by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the tailpipe cover by installing the bolts WARNING EWB01910 1 Bolt 2 Tailpipe cover 1 Tailpipe 2 Spark arrester POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system U3D510E0 book Page 21 Friday December 2 2005 1 07 PM ...

Page 103: ...fter removing the plug have a Yamaha dealer check the ATV as the water may affect other engine parts 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 exhaust components Do not start the engine when cl...

Page 104: ... The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart NOTE A...

Page 105: ...nance and lubrication chart The throttle cable free play should measure 3 0 5 0 mm 0 12 0 20 in as shown Periodically check the throttle cable free play and if necessary adjust it as follows NOTE The engine idling speed must be checked and 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...

Page 106: ...and adjusted at the intervals specified in the periodic maintenance and lubrication chart EBU24120 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart EBU24171 Front brake pads Check each front brake pad for damage and mea sure the lining thickness If a...

Page 107: ...k EBU24251 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly causing it to become inef fective Before riding check that the brake fluid is above the minimum level mark and replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the 1 Lining thickness 1 Wear limit line 2 Wear indicator U3D510E...

Page 108: ...id 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 EBU24280 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the peri odic maintenance and lubrication chart In addi tion have the oil seals of the br...

Page 109: ...e play must be checked and if necessary adjusted at the inter vals specified in the periodic maintenance and lu brication 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 drag Make sure the brake...

Page 110: ...rrect adjust it as follows 1 Fully loosen the brake lever free play adjust ing nut on the brake cable at the rear wheel Adjusting the brake lever free play The brake lever free play should measure 3 0 5 0 mm 0 12 0 20 in as shown If the free play is in correct adjust it as follows 1 Brake pedal free play 1 Brake lever free play adjusting nut 2 Brake pedal free play adjusting nut U3D510E0 book Page...

Page 111: ...the rear wheel hub so that gap A measures 0 1 mm 0 0 04 in 3 Turn the brake lever free play adjusting bolt at the brake lever in direction a to increase the free play and in direction b to decrease it 1 Brake lever free play 2 Locknut 3 Brake lever free play adjusting bolt 1 Brake lever free play adjusting nut 2 Gap A U3D510E0 book Page 30 Friday December 2 2005 1 07 PM ...

Page 112: ...r the brake pedal can be adjusted as follows but the other brake light switches should be adjusted by a Yamaha dealer 1 Remove panel A See page 8 8 1 Locknut 2 Brake lever free play adjusting bolt POTENTIAL HAZARD WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is cor...

Page 113: ...e is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWB02120 EBU24911 1 Brake light switch 2 Brake light switch adjusting nut 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 control...

Page 114: ...wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease all purpose grease U3D510E0 book Page 33 Friday December 2 2005 1 07 PM ...

Page 115: ... Lubricating the steering shaft The steering shaft must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart EBU25211 Battery This model is equipped with a sealed type MF battery which does not require any maintenance There is no need to check the electrolyte or to add distilled water Check and if necessary tighten the battery lead connections CAUTION ECB006...

Page 116: ...charged 1 Install the battery 2 Make sure to properly connect the battery leads to the battery terminals POTENTIAL HAZARD Failure to handle batteries or battery electro lyte carefully WHAT CAN HAPPEN You could be poisoned 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 w...

Page 117: ...led 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 EBU25312 Replacing a fuse 1 Positive battery terminal 2 Negative battery terminal 1 Main fuse 2 Spare main fuse 3 Fuse box U3D510E0 book Page 36 Friday December 2 2005 1 07 PM ...

Page 118: ...amperage WARNING EWB02151 1 Headlight fuse 2 Ignition fuse 3 Signaling system fuse 4 Spare fuse Specified fuses Main fuse 20 0 A Headlight fuse 15 0 A Ignition fuse 15 0 A Signaling system fuse 10 0 A 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 specifie...

Page 119: ...ulling it off 2 Remove the headlight bulb holder by pushing it inward and turning it counterclockwise 3 Remove the defective bulb from the headlight unit by pulling it out WARNING EWB02180 1 Headlight bulb holder cover 1 Headlight bulb holder 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...

Page 120: ...nd the bulb life will be adversely affect ed Thoroughly clean off any dirt and finger 5 Install the headlight bulb holder by aligning the projections with the holes in the headlight unit pushing it inward and turning it clockwise until it stops 6 Install the headlight bulb holder cover at the rear of the headlight 7 Adjust the headlight beam if necessary EBU25560 Adjusting a headlight beam ECB0069...

Page 121: ...ection 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 U3D510E0 book Page 40 Friday December 2 2005 1 07 PM ...

Page 122: ...ens 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 U3D510E0 book Page 41 Friday December 2 2005 1 07 PM ...

Page 123: ... ground 3 Tighten the wheel nuts to the specified torques 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U3D510E0 book Page 42 Friday December 2 2005 1 07 PM ...

Page 124: ...o 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 expensive repair bills WARNING EWB02260 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame HO...

Page 125: ...ve 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 Have a Yamaha dealer The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The battery is good Dry Wet Ope...

Page 126: ...10 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 surfaces wit...

Page 127: ...osen 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 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the WHAT CAN HA...

Page 128: ...s 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 prevent moisture from entering it 9 Remove the battery an...

Page 129: ...Weight With oil and fuel 229 0 kg 505 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Compression ratio 9 20 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 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 2...

Page 130: ...gal 0 99 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BSR33 x 1 Spark plug s Manufacturer model NGK DR8EA Spark plug gap Transmission Primary reduction system V belt Secondary reduction system Shaft drive Secondary reduction ratio 41 21 24 18 33 9 9 545 Transmission type V belt automatic Operation Left hand operation Forward gear 35 20 1 750 Reverse gear 26 15 1 733 Chassis Frame type St...

Page 131: ...a 3 2 psi 0 22 kgf cm Rear 22 kPa 3 2 psi 0 22 kgf cm Maximum Front 28 kPa 4 1 psi 0 28 kgf cm Rear 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 Type Drum brake Operation Left hand and right foot operation Front suspension Type Double wishbone Spring shock absorber type C...

Page 132: ... Ah Headlight Bulb type Krypton bulb Bulb voltage wattage x quantity Headlight 12 V 30 W 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Oil temperature warning light 12 V 1 7 W 1 Signaling system fuse 10 0 A Ignition fuse 15 0 A U3D510E0 book Page 4 Friday December 2 2005 1 07 PM ...

Page 133: ...ef 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 identifica...

Page 134: ... EBU26050 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 1 Model label U3D510E0 book Page 2 Friday December 2 2005 1 07 PM ...

Page 135: ...e 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 Muff...

Page 136: ...e 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 U3D510...

Page 137: ...quent 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 warra...

Page 138: ...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 con...

Page 139: ... 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 140: ...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 U3D510E0 book Page 8 Friday December 2 2005 1 0...

Page 141: ...11 EBU26132 U3D510E0 book Page 9 Friday December 2 2005 1 07 PM ...

Page 142: ...g 8 33 Brakes front and rear 5 4 C Cables checking and lubricating 8 32 Carburetor adjusting 8 23 Chassis fasteners 5 8 Cleaning 9 1 D E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 23 Engine oil 5 3 Engine oil and oil filter cartridge 8 11 Engine starting a warm 6 3 Engine stop switch 4 3 F Final gear oil 5 3 8 15 Fuel 4 8 5 3 Fuel cock 4 10 Fuel tank cap 4 8 Fuses replacing 8 ...

Page 143: ...g your ATV 7 1 S Safety information 1 1 Seat 4 12 Starter choke 4 11 Start switch 4 3 Steering shaft lubricating 8 34 Storage 9 2 Storage compartment 4 13 T Tail brake light bulb replacing 8 40 Throttle cable free play adjusting 8 24 Throttle lever 4 4 5 5 Tire pressure measuring 5 7 Tires 5 6 Tire wear limit 5 8 Troubleshooting 8 43 Troubleshooting chart 8 44 V Valve clearance 8 25 V belt case dr...

Page 144: ...ct 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 PROTECTIVE GEAR NEVER USE ON PU...

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