Yamaha WOLVERINE YFM45FXV Owner'S Manual Download | Manualshive

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Removing and installing cowlings

and panels..................................... 8-6

Engine oil and oil filter cartridge .... 8-14
Final gear oil .................................. 8-19
Differential gear oil replacement ... 8-22
Cooling system.............................. 8-24
Changing the coolant .................... 8-26
Axle boots...................................... 8-29
Spark plug inspection .................... 8-30
Air filter element cleaning .............. 8-32
V-belt cooling duct check hose ..... 8-35
V-belt case drain plug.................... 8-36
Spark arrester cleaning ................. 8-36
Carburetor adjustment................... 8-38
Idle speed adjustment ................... 8-38
Valve clearance adjustment .......... 8-39
Select lever safety system

cable adjustment ......................... 8-39

Throttle lever adjustment............... 8-40
Front brake pad check .................. 8-40
Rear brake pad check ................... 8-41
Inspecting the brake fluid level...... 8-42
Brake fluid replacement................. 8-43

Front brake lever free play.............8-44
Adjusting the rear brake lever and

brake pedal ..................................8-45

Adjusting the rear brake light

switch ...........................................8-47

Cable inspection and

lubrication.....................................8-48

Lubricating the brake levers and

brake pedal ..................................8-48

Wheel removal ...............................8-49
Wheel installation...........................8-50
Battery............................................8-51
Battery maintenance......................8-52
Fuse replacement ..........................8-53
Replacing a headlight bulb ............8-55
Headlight beam adjustment...........8-58
Tail/brake light bulb

replacement .................................8-58

Troubleshooting .............................8-59
Troubleshooting charts ..................8-61

U3C210.book Page 3 Tuesday, June 21, 2005 10:54 AM

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Summary of Contents for WOLVERINE YFM45FXV

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

Page 2: ...EBU00776 ...

Page 3: ...nformation It provides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV ...

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

Page 5: ...l applicable OFF ROAD noise level and spark arrester laws and regu lations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU01067 YFM45FXV OWNER S MANUAL 2005 by Yamaha Motor Corporation U S A 1st edition June 2005 All rights reserved Any reprinting or unauthorized use without the written permission of U3C210 book Page 2 Tuesday ...

Page 6: ...ication number 3 2 Vehicle identification number 3 3 1 2 3 Indicator and warning lights 4 2 Speedometer unit 4 3 Handlebar switches 4 4 Throttle lever 4 7 Speed limiter 4 8 Front brake lever 4 9 Brake pedal and rear brake lever 4 9 Drive select lever 4 10 Fuel tank cap 4 10 Fuel cock 4 11 Starter choke 4 12 Seat 4 13 Storage compartment 4 14 Front shock absorber adjustment 4 15 Rear shock absorber...

Page 7: ...n and reverse driving 6 4 Engine break in 6 7 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 22 Climbing uphill 7 24 Riding downhill 7 30 Crossing a slope 7 32 Crossing through shallow water 7 34 Riding over rough terrain 7 37 Sliding and skidding 7 38 What to do if 7 40 What to do 7 40 PERIODIC MAINTENANCE A...

Page 8: ...t 8 38 Idle speed adjustment 8 38 Valve clearance adjustment 8 39 Select lever safety system cable adjustment 8 39 Front brake lever free play 8 44 Adjusting the rear brake lever and brake pedal 8 45 Adjusting the rear brake light switch 8 47 Cable inspection and lubrication 8 48 Lubricating the brake levers and brake pedal 8 48 Wheel removal 8 49 Wheel installation 8 50 Battery 8 51 Battery maint...

Page 9: ... 1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 9 10 11 12 13 14 U3C210 book Page 4 Tuesday June 21 2005 10 54 AM ...

Page 10: ...EBU00464 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS U3C210 book Page 1 Tuesday June 21 2005 10 54 AM ...

Page 11: ...achine They contain important information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 U3C210 book Page 2 Tuesday June 21 2005 10 54 AM ...

Page 12: ...ING YAMAHA 4XE F415A 00 NEVER operate this ATV if you are under age 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death U3C210 book Page 3 Tuesday June 21 2005 10 54 AM ...

Page 13: ...5 U3C210 book Page 4 Tuesday June 21 2005 10 54 AM ...

Page 14: ...ut proper training or instruction Take a Training Course Begin ners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc Never allow a child under age 16 to operate an...

Page 15: ...ou use it to make sure it is in safe operating condition Al ways follow the inspection and maintenance procedures and schedules described in this man ual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV ...

Page 16: ...e hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if pos...

Page 17: ...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 pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for an ATV Cargo should be ...

Page 18: ...f ignition such as the pilot lights of water heaters and clothes dry When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapo...

Page 19: ...n a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation U3C210 book Page 6 Tuesday June 21 2005 10 54 AM ...

Page 20: ... case 9 Fuel cock 10 Air filter case 11 Fuses 12 Storage compartment and tool kit 15 Engine oil dipstick 16 Oil filter cartridge 17 Coolant reservoir 18 V belt cooling duct check hose 19 Rear brake lever 20 Left handlebar switches 21 Starter choke 22 Drive select lever 23 Main switch 24 Speedometer unit 25 Fuel tank cap 26 On Command four wheel drive switch 27 Front brake lever U3C210 book Page 1 ...

Page 21: ...g spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number U3C210 book Page 2 Tuesday June...

Page 22: ...hicle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label U3C210 book Page 3 Tuesday June 21 2005 10 54 AM ...

Page 23: ...09420 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position 1 Main switch U3C210 book Page 1 Tuesday June 21 2005 10 54 AM ...

Page 24: ...is light comes on to warn that the coolant temperature is too hot If the light comes on during operation stop the en gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes CAUTION _ The engine may overheat if the ATV is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is o...

Page 25: ...is indicator light comes on when the 2WD 4WD switch is in the 4WD position NOTE _ Due to the synchronizing mechanism in the differential gear case the light may not come on until the ATV starts moving _ EBU26181 Speedometer unit 1 Speedometer 2 Odometer Tripmeter 3 SELECT button The speedometer unit is equipped with the following a speedometer which shows the riding speed an odometer which shows t...

Page 26: ... to estimate the dis tance that can be traveled with a full tank of fu el This information will enable you to plan future fuel stops NOTE _ Pushing in the SELECT button then turning the key to ON and keeping them in this po sition for at least two seconds switches the display between mph and km h _ EBU00053 Handlebar switches 1 Light switch OFF 2 Engine stop switch 3 Start switch EBU12040 Light sw...

Page 27: ...re that the engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is set to EBU00607 Start switch The starter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engi...

Page 28: ...from 2WD to 4WD or from 4WD to 2WD while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD in some circumstances Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause the ATV to unexpectedly handle differ ently This could distract the operator and increase the risk of losing control and an accident HOW TO AVOID THE HAZARD Always stop the ATV before chang...

Page 29: ...ngine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever bef...

Page 30: ...No more than 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to...

Page 31: ... front brake lever is located on the right handlebar Pull it toward the handlebar to ap ply the front brake 1 Front brake lever EBU00732 Brake pedal and rear brake lever 1 Brake pedal U3C210 book Page 9 Tuesday June 21 2005 10 54 AM ...

Page 32: ...hine into the forward neutral reverse and park positions Refer to page 6 4 for the drive select lever operation 1 Drive select lever EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap U3C210 book Page 10 Tuesday June 21 2005 10 54 AM ...

Page 33: ...nning ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON position 1 Arrow mark positioned over OFF OFF Position ON Position U3C210 book...

Page 34: ...r air fuel mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 RES Position U3C210 book Page 12 Tuesday June 21 2005 10 54 AM ...

Page 35: ...EBU26200 Seat To remove the seat push the seat lock lever backward and pull up the seat at the rear 1 Seat 1 Seat lock lever U3C210 book Page 13 Tuesday June 21 2005 10 54 AM ...

Page 36: ... for seat removal and installation procedures When storing any documents in the storage compartment be sure to wrap them in a plas tic bag so that they will not get wet When washing the ATV be careful not to let any wa ter enter the storage compartment NOTE _ If any water collects in the storage compart ment remove the drain plugs at the bottom of the storage compartment drain the water and then i...

Page 37: ...it the rider s weight and riding conditions Adjust the spring preload as follows To increase the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring U3C210 book Page 15 Tuesday June 21 2005 10 54 AM ...

Page 38: ...Maximum hard WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set ting U3C210 book Page 16 Tuesday June 21 2005 10 54 AM ...

Page 39: ...rease the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ 1 Special wrench Standard position 2 1 Minimum soft 5 Maximum hard U3C210 book Page 17 Tuesday June 21 2005 10 54 AM ...

Page 40: ...EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death U3C210 book Page 18 Tuesday June 21 2005 10 54 AM ...

Page 41: ...5 3 8 41 8 43 8 45 8 46 Fuel Check fuel level Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 6 8 14 8 19 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 7 8 24 8 29 Final gear oil and differential gear oil Check for leakage 5 6 8 19 8 24 Throttle Check for proper throttle cable operation and free play 5 7 8 40 Wheels ...

Page 42: ...pedal They should move smoothly and there should be a firm feeling when the brakes are applied If not have a Yamaha dealer inspect the brake system Brake fluid level WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper ating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV ea...

Page 43: ...y are working properly If the brakes do not provide proper braking per formance inspect the brake pads for wear See pages 8 40 8 41 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with ...

Page 44: ...igned to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 14 5 L 3 19 Imp gal 3 83 US gal Reser...

Page 45: ...HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure th...

Page 46: ...ake sure that no foreign material en ters the crankcase _ EBU00493 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 19 8 22 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used EBU00678 Differential gear oil Make sure th...

Page 47: ...ls CAUTION _ Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water _ EBU01083 Throttle lever Check to see that the throttle lever operates Coolant reservoir capacity WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure H...

Page 48: ...n of all switches Have a Yamaha dealer repair as necessary for proper operation EBU00157 Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of acci dent HOW TO AVOID THE HAZARD ...

Page 49: ...d could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 37 kPa 0 37 kgf cm2 5 3 psi Rear 37 kPa 0 37 kgf cm2 5 3 psi 4 Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fa...

Page 50: ... reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifica tions ACE 02EACE 02E 1 Low pressure tire gauge Recommended pressure Minimum Maximum Front 40 kPa 0 40 kgf cm2 5 8 psi 37 kPa 0 37 kgf cm2 5 3 psi 43 kPa 0 43 kgf cm2 6 1 psi 40 kPa 37 kPa 43 kPa U3C210 book Page 10 Tuesday June 21 2005 10 54 AM...

Page 51: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit U3C210 book Page 11 Tuesday June 21 2005 10 54 AM ...

Page 52: ...th all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW TO AV...

Page 53: ... park before starting the engine _ 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warm ing up position Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 6 Comple...

Page 54: ...starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding CAUTION _ See the Engine break in section prior to operating the engine for the first time _ EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used The ...

Page 55: ...aged _ Shifting Neutral to Forward 1 Bring the ATV to a complete stop and re turn the throttle lever to the closed posi tion 2 Apply the brakes then shift by moving the drive select lever along the shift guide NOTE _ Make sure that the drive select lever is com pletely shifted into position 1 Drive select lever 3 Open the throttle lever gradually U3C210 book Page 4 Tuesday June 21 2005 10 54 AM ...

Page 56: ... brake pedal 3 Shift from neutral to reverse or from re verse to park and vice versa by moving the drive select lever along the shift guide 1 Drive select lever NOTE _ When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the electrical circuit Due to the synchronizing mechanism in the engine the light may not come on un til the ATV s...

Page 57: ...properly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slow ly U3C210 book Page 6 Tuesday June 21 2005 10 54 AM ...

Page 58: ...h might result in ex cessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this pe...

Page 59: ...ll throttle at any time After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00612 Parking When parking stop the engine and shift the drive select lever into the park position then turn the fuel cock to the OFF position U3C210 book Page 8 Tuesday June 21 2005 10 54 AM ...

Page 60: ... HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the machine transversely across the in cline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easi...

Page 61: ...a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object atta...

Page 62: ...ke sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with controls or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slow er you should go Allow more braking distance A heavier ve hicle takes longer to stop Avoid making sharp turns unless at very slow speeds...

Page 63: ...n vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking U3C210 book Page 12 Tuesday June 21 2005 10 54 AM ...

Page 64: ...EBU26210 WARNING _ Indicates a potential hazard that could result in serious injury or death U3C210 book Page 13 Tuesday June 21 2005 10 54 AM ...

Page 65: ...7 1 Riding Your ATV U3C210 book Page 1 Tuesday June 21 2005 10 54 AM ...

Page 66: ... prac tice Take your time to fully learn techniques before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you the operation of the controls Pay particular at tention to the safety inform...

Page 67: ... time Take the time to learn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills le...

Page 68: ...mmenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc U3C210 book Page 5 Tuesday June 21 2005 10 54 AM ...

Page 69: ...EN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers U3C210 book Page 6 Tuesday June 21 2005 10 54 AM ...

Page 70: ...accident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long slee...

Page 71: ...ARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV U3C210 book Page 8 Tuesday June 21 2005 10 54 AM ...

Page 72: ...V is in safe op erating condition Always follow the inspection and main WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use the size ...

Page 73: ...op speed of the ATV Turning the adjusting screw in decreases the top speed and turning it out increases the top speed See page 4 8 for details 1 Locknut 2 Adjusting screw WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always ...

Page 74: ...ehicle loading limit 100 kg 220 lb Total weight of rider cargo and accessories Storage compartment 2 0 kg 4 lb WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed an...

Page 75: ...even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation U...

Page 76: ...G POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off U3C210 book Page 13 Tuesday June 21 2005 10 54 AM ...

Page 77: ...cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed U3C210 book Page 14 Tuesday June 21 2005 10 54 AM ...

Page 78: ...WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it U3C210 book Page 15 Tuesday ...

Page 79: ... this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets U3C210 book Page 16 Tuesday June 21 2005 10 54 AM ...

Page 80: ...erating 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 U3C210 book Page 17 Tuesday June 21 2005 10 54 AM ...

Page 81: ...NG POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturn ing or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar terrain U3C210 book Page 18 Tuesday June 21 2005 10 54 AM ...

Page 82: ...r vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain U3C210 book Page 19 Tuesday June 21 2005 10 54 AM ...

Page 83: ...er hitch Do not ride in areas posted no trespassing Do not ride on private property without getting permission WARNING WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles U3C210 book Page 20 Tuesday June 21 2005 10 54 AM ...

Page 84: ... riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling return the starter choke to the closed position and shift the drive select lever into the forward position Ap ply the throttle slowly and smoothly The cen trifugal clutch will engage and you will start to accelerate If the throttle is applied too abrupt ly the front wheels may lift ...

Page 85: ... As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control...

Page 86: ...mproper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember A...

Page 87: ...rtant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small ...

Page 88: ...as described in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards An obstacle a sharp drop or another vehicle or person could be on the other side of the hill U3C210 book Page 25 Tuesday June 21 2005 10 54 AM...

Page 89: ...ENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible U3C2...

Page 90: ...a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV U3C210 book Page 27 Tuesday June 21 2005 10 54 AM ...

Page 91: ... nected by the drive train This means that ap plying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid and rear brakes gradually or dismount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbin...

Page 92: ...topped shift to the parking position P 4WD Apply both front and rear brakes gradually When fully stopped shift to the parking position P Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu al U3C210 book Page 29 Tuesday June 21 2005 10 54 AM ...

Page 93: ... a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake le ver or the brake pedal will brake the wheels on the downhill side Avoid sudden applica tion of either the front or rear brake because the wheels on the uphill s...

Page 94: ...ing down hills as described in this Own er s Manual Note a special technique is required when braking as you go down a hill HOW TO AVOID THE HAZARD Always check the terrain carefully be fore you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that U3C210 book Page 31 Tuesday June 21 2005 10 54 AM ...

Page 95: ...y up hill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill unt...

Page 96: ...U3C210 book Page 33 Tuesday June 21 2005 10 54 AM ...

Page 97: ...ery or up set the ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to l...

Page 98: ...ed water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hose and the storage compartment drain plugs Also remove the V belt case drain plug to drain any water that may have accumulated Wash the ATV in fresh water if it has been operated in salt water or muddy conditions _ U3C210 book Page 35 Tuesday June 21 2005 1...

Page 99: ...1 V belt cooling duct check hose left front side of ATV 1 Storage compartment drain plug 2 U3C210 book Page 36 Tuesday June 21 2005 10 54 AM ...

Page 100: ...ol and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper procedu...

Page 101: ...heels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide U3C210 book Page 38 Tuesday June 21 200...

Page 102: ...ntrol may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious ...

Page 103: ...If necessary gradually let off the throttle and or steer to the outside of the turn See If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerat ing is not recommended until you have cor rected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for ward...

Page 104: ...over that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV un til you have regained adequate braking ability See...

Page 105: ...manual and tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it on the bottom of the seat as shown Put the own er s tool kit and low pressure tire gauge under the seat WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or c...

Page 106: ...our machine to a Yamaha dealer to check the torque settings and adjust them as neces sary _ WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er inst...

Page 107: ...k should be performed by a Yamaha dealer as they require special tools data and technical skills _ ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 300 800 2 500 1 600 2 500 1 600 5 000 3 200 hours 20 80 160 160 320 Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Carburetor Check starter choke op...

Page 108: ...Warm engine before draining Engine oil filter cartridge Replace Engine oil strainer Clean Final gear oil Check oil level oil leakage Replace every 12 months Differential gear oil Front brake Check operation fluid leakage See NOTE page 8 5 Correct if necessary Rear brake Check operation fluid leakage See NOTE page 8 5 Correct if necessary Select lever safety system cable Check operation Adjust if n...

Page 109: ...r if cracked or damaged WARNING _ Indicates a potential hazard that could result in serious injury or death Engine mount Check for cracks or damage Axle boots Check operation Replace if damaged Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check operation Adjust headlight beams ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6...

Page 110: ...rated need to be removed to perform some of the mainte nance described in this chapter Refer to this section each time a cowling or a panel has to be removed or reinstalled 1 Panel A 1 Panel B 2 Cowling A 3 Cowling B 4 Panel C 5 Panel D U3C210 book Page 6 Tuesday June 21 2005 10 54 AM ...

Page 111: ... installation procedures 2 Remove panel B See page 8 12 for re moval and installation procedures 3 Disconnect the speedometer unit cou plers 1 Speedometer unit coupler 2 4 Remove cowling A by removing the bolts nuts and washers 1 Bolt U3C210 book Page 7 Tuesday June 21 2005 10 54 AM ...

Page 112: ... left side To install 1 Connect the speedometer unit couplers 2 Install cowling A by installing the bolts nuts and washers 3 Install panel B 4 Install cowling B U3C210 book Page 8 Tuesday June 21 2005 10 54 AM ...

Page 113: ...e out of the handlebar cover 1 Fuel tank breather hose 2 Handlebar cover 4 Remove the fuel tank cap by turning it counterclockwise CAUTION _ Make sure that no foreign material en ters the fuel tank Be sure to install the fuel tank cap im mediately after removing and install ing the cowling _ U3C210 book Page 9 Tuesday June 21 2005 10 54 AM ...

Page 114: ...5 Remove the cowling by removing the bolts 1 Bolt 4 1 Bolt left side U3C210 book Page 10 Tuesday June 21 2005 10 54 AM ...

Page 115: ...4 Place the handlebar cover in the original position 5 Pass the fuel tank breather hose through the hole of the handlebar cover 6 Install the seat EBU01147 Panel A To remove Remove the bolt and then take the panel off To install Place the panel in the original position and in stall the bolt CAUTION _ When installing the panel be sure not to pinch the cables or wires _ U3C210 book Page 11 Tuesday J...

Page 116: ...Panel B To remove Pull outward on the areas shown 1 Panel B To install Insert the tabs on the panel into the slots in cowling A and push inward 1 Tab 6 2 Slot 6 U3C210 book Page 12 Tuesday June 21 2005 10 54 AM ...

Page 117: ... and then take the panel off To install Place the panel in the original position and then install the bolts 1 Panel C 2 Bolt 3 EBU06380 Panel D To remove Pull outward on the areas shown 1 Panel D U3C210 book Page 13 Tuesday June 21 2005 10 54 AM ...

Page 118: ...ecified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Remove panel D See pages 8 13 8 14 for panel removal and installation proce dures 3 Start the engine warm it up for several minutes and then turn it off 4 Wait a few minutes until the oil settles 5 Remove the engine oil filler cap and wipe off the dipstick with a clean rag U...

Page 119: ...tween the mini mum and maximum level marks _ 1 Maximum level mark 2 Minimum level mark 7 If the engine oil is at or below the mini mum level mark add sufficient oil of the recommended type to raise it to the cor rect level 8 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 9 Install the panel U3C210 book Page 15 Tuesday June 21 2005 10 54 AM ...

Page 120: ...lace an oil pan under the engine to col lect the used oil and then remove the en gine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase NOTE _ Skip steps 5 9 if the oil filter cartridge is not being replaced _ 5 Remove panel C See page 8 13 for panel removal and installation proce dures 6 Remove the oil filter cartridge with an oil filter wrench U3C210 book Page...

Page 121: ...ng of the new oil filter cartridge NOTE _ Make sure the O ring is seated properly _ 1 O ring 8 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf U3C210 book Page 17 Tuesday June 21 2005 10 54 AM ...

Page 122: ... oils with a diesel specification of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 2 30 L 2 02 Imp qt 2 43 US qt With oil filter cartridge replacement 2 40 L 2 11 Imp qt 2 54 ...

Page 123: ...t if necessary 14 Install panel D EBU11453 Final gear oil Checking the final gear oil 1 Place the ATV on a level surface 2 Remove the oil filler bolt and then check the oil level in the final gear case NOTE _ The oil level should be at the brim of the filler hole _ 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level U3C210 b...

Page 124: ...t and then tighten it to the specified torque Replacing the final gear oil 1 Remove the final gear case cover by re moving the bolts 1 Final gear case cover 2 Bolt 2 2 Place the ATV on a level surface 3 Place a container under the final gear case to collect the used oil 4 Remove the oil filler bolt and the drain U3C210 book Page 20 Tuesday June 21 2005 10 54 AM ...

Page 125: ...d then tighten it to the specified torque 8 Check for oil leakage If oil leakage is found check for the cause 9 Install the final gear case cover bolts and Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 23 L 0 20 Imp qt 0 24 US qt Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf U3C210 book ...

Page 126: ... container under the differential gear case to collect the used oil 3 Remove the oil filler bolt and oil drain bolt to drain the oil 1 Differential case oil filler bolt Tightening torque Final gear case cover bolt 16 Nm 1 6 m kgf 11 ft lbf U3C210 book Page 22 Tuesday June 21 2005 10 54 AM ...

Page 127: ...g will cause the oil to seep out of the breather hose during and after riding The differential gear oil level cannot be checked The differential gear case ca pacity is greater than the recommended oil quantity therefore the oil level cannot be accurately checked from the oil filler cap hole _ Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Recommended oil SAE 80 API G...

Page 128: ...or the cause EBU10152 Cooling system 1 Place the ATV on a level surface 2 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine tem perature NOTE _ The coolant should be between the minimum and maximum level marks _ Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf U3C210 book Page 24 Tuesday June 21 2005 10 ...

Page 129: ...soft water if you can not get distilled water _ NOTE _ If water is added have a Yamaha dealer check the antifreeze content of the cool ant as soon as possible The radiator fan operation is completely automatic It is switched on or off accord ing to the coolant temperature in the radi ator _ If your ATV overheats see page 8 62 for de tails Coolant reservoir capacity up to the maximum level mark 0 2...

Page 130: ...similar object as shown to prevent coolant from spilling on the footrest WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag over the cap Allow any re maining press...

Page 131: ...nstallation procedures 1 Radiator cap 5 Remove the radiator cap 6 Remove the coolant reservoir cap 7 Disconnect the hose on the coolant res ervoir side and then drain the remaining coolant from the coolant reservoir U3C210 book Page 27 Tuesday June 21 2005 10 54 AM ...

Page 132: ... reservoir to the maximum level mark and then install the reservoir cap 12 Pour the recommended coolant into the radiator until it is full and then install the radiator cap Tightening torque Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze and water mixing ratio 1 1 Total amount 1 32 L 1 16 Imp qt 1 40 US qt Coolant rese...

Page 133: ...radiator If it is low add more coolant until it reaches the top of the radiator 14 Check for coolant leakage NOTE _ If any leakage is found have a Yamaha deal er check the cooling system _ 15 Install the cowling 16 Install the panels EBU00862 Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by a Yamaha dealer 1 Axle boot 2 each side U3C210 book Pag...

Page 134: ...rk plug wrench in the owner s tool kit to remove the spark plug as shown 1 Spark plug wrench Inspection The spark plug is an important engine compo nent and is easy to inspect The condition of the spark plug can indicate the condition of the engine U3C210 book Page 30 Tuesday June 21 2005 10 54 AM ...

Page 135: ...rk plug with the specified plug Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification a Spark plug gap 2 Clean the surface of the spark plug gas ket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug and tighten it to the specified torque Specified spark plug DR8EA NGK Spark plug ga...

Page 136: ...pecified torque as soon as possible _ 4 Install the spark plug cap EBU15140 Air filter element cleaning NOTE _ There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seat See pages 4 13 4 14 U3C210 book Page 32 Tuesday June 21 2005 10 54 AM ...

Page 137: ...r element assembly 4 Pull off the lock plate and then remove the air filter element from its frame 1 Air filter element frame 2 Air filter element 3 Lock plate 5 Wash the element gently but thoroughly in solvent U3C210 book Page 33 Tuesday June 21 2005 10 54 AM ...

Page 138: ...ter element over its frame and then install the lock plate 10 Install the air filter element assembly 11 Install the air filter case cover by hooking the fasteners onto the air filter case 12 Install the seat WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOI...

Page 139: ...tight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine _ CAUTION _ Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration without the air filter element will af EBU06411 V belt cooling duct check hose If dust or water collects i...

Page 140: ...ter re moving the plug have a Yamaha dealer in spect the ATV as the water may affect other engine parts _ EBU26250 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the tailpipe cover by removing the bolts 2 Remove the tailpipe by pulling it out of the muffler 1 Bolt 3 2 Tailpipe cover U3C210 book Page 36 Tuesday June 21 2005 10 54 AM...

Page 141: ...rrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool pri or to touching exhaust components Do not start the engine when cleaning the exhaust system U3C210 book Page 37 Tuesday June 21 2005 10 54...

Page 142: ...nowledge poor engine perfor mance and damage may result EBU13020 Idle speed adjustment NOTE _ A diagnostic tachometer must be used for this procedure _ 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer to the spark plug lea...

Page 143: ...adjusted regularly This adjust ment however should be left to a professional Yamaha service technician EBU03050 Select lever safety system cable adjustment The select lever safety system cable stretch es with use resulting in improper function To prevent this the cable must be adjusted regularly This adjustment however should be left to a Yamaha dealer U3C210 book Page 39 Tuesday June 21 2005 10 5...

Page 144: ...l the throttle le ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut EBU13090 Front brake pad check Check the brake pads for damage and wear If a brake pad thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the pads as a set a Brake pad thickness NOTE _ The wheels need to be removed to check the U3C210 book Page 40 Tuesday June 21 2005 10 54 AM ...

Page 145: ...ut disassembling the brake Check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared ask a Yamaha dealer to replace the pads as a set NOTE _ The wheels need to be removed to check the brake pads See pages 8 49 8 50 for wheel removal and installation procedures _ U3C210 book Page 41 Tuesday June 21 2005 10 54 AM ...

Page 146: ...plenish when necessary A low brake fluid level may indicate worn brake pads and or brake sys tem leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage The rear brake fluid master cylinder reservoir is located under cowling B See pages 8 9 8 11 for cowling removal and installation procedures 1 Minimum level mark FRONT REAR U3C210 book Page...

Page 147: ...illing Water will significantly lower the boiling point of the fluid and may result in vapor Brake fluid may deteriorate painted surfac es or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer check the cause if the brake fluid level goes down EBU11860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel Have a Yamaha ...

Page 148: ...ng with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re U3C210 book Pag...

Page 149: ...he locknut 1 Locknut 2 Adjusting bolt c Rear brake lever free play 2 Turn the adjusting bolt in direction a to If correct free play cannot be obtained ask a Yamaha dealer to make that adjustment NOTE _ When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move _ U3C210 book Page 45 Tuesday June 21 2005 10 54 AM ...

Page 150: ...g with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag All air must be bled from the brake system Replacement of brake components re quires professional knowledge These U3C210 book Page...

Page 151: ...ke light switch as follows 1 Remove panel A See page 8 11 for panel removal and installation proce dures 2 Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjust ing nut in direction b 3 Install the panel 1 Rear brake light switch 2 Adjusting nut U3...

Page 152: ... 8 11 for panel removal and in stallation procedures _ WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Recomm...

Page 153: ... Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 U3C210 book Page 49 Tuesday June 21 2005 10 54 AM ...

Page 154: ...red nuts are used for both the front and rear wheels Install the nut with its ta pered side towards the wheel _ 1 Tapered nut 2 Lower the ATV so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf U3C210 book Page 50 Tuesday June 21 2005 10 54 AM ...

Page 155: ... Negative battery terminal 2 Positive battery terminal CAUTION Do not try to remove the sealing caps of the battery cells You may damage the bat tery WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WHAT CAN HAPPEN You could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases U3C210 book Page 51...

Page 156: ...e correct when putting the battery back in the machine HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 ...

Page 157: ...is blown turn off the main switch and the switch of the circuit in question Then install a new fuse of the specified amperage Turn on the main switch If the fuse immediately blows again con sult a Yamaha dealer 1 Main fuse 2 Spare main fuse 3 Fuse box U3C210 book Page 53 Tuesday June 21 2005 10 54 AM ...

Page 158: ...turn off the main switch when checking or replacing a fuse _ Specified fuses Main fuse 30A Headlight fuse 15A Ignition fuse 10A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse U3C210...

Page 159: ...rns out replace it as fol lows 1 Remove the headlight bulb holder cover at the rear of the headlight by pulling it off 1 Headlight bulb holder cover 2 Remove the headlight bulb holder by 1 Headlight bulb holder U3C210 book Page 55 Tuesday June 21 2005 10 54 AM ...

Page 160: ...e headlight unit 1 Do not touch the glass part of the bulb WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it U3C210 book Page 56 Tuesday June 21 2005 10 54 AM ...

Page 161: ... Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner _ 5 Install the headlight bulb holder by align ing 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 U3C210 book Page 57 Tuesday June 21 2005 10 54 AM...

Page 162: ...am turn the adjusting bolt in di rection a To lower the beam turn the adjusting bolt in direction b EBU12170 Tail brake light bulb replacement 1 Screw 2 1 Remove the lens by removing the screws 2 Remove the defective bulb by pushing it inward and turning it counterclockwise U3C210 book Page 58 Tuesday June 21 2005 10 54 AM ...

Page 163: ...gnition sys tems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it to a Yamaha dealer The skilled technicians at a Yamaha dealer ship have the tools experience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamah...

Page 164: ...PEN Fuel can ignite or explode causing se vere injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnac es U3C210 book Page 60 Tuesday June 21 2005 10 54 AM ...

Page 165: ...the electric starter to see if there is compression There is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap Check the fuel flow T...

Page 166: ...ver the cap Al low any remaining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the coolant reservoir and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See NOTE Restart the engine If the engine overheats again ask...

Page 167: ...xles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash ers 4 Once the m...

Page 168: ... may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the ...

Page 169: ...ablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing in a humid or salt a...

Page 170: ...dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine U3C210 book Page 4 Tuesday June 21 2005 10 54 AM ...

Page 171: ... 1 233 mm 48 5 in Ground clearance 220 mm 8 66 in Minimum turning radius 3 000 mm 118 1 in Basic weight With oil and full fuel tank 250 0 kg 551 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 421 0 cm3 Bore stroke 84 5 75 0 mm 3 33 2 95 in Compression ratio 10 00 1 U3C210 book Page 1 Tuesday June 21 2005 10 54 AM ...

Page 172: ... 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher U3C210 book Page 2 Tuesday June 21 2005 10 54 AM ...

Page 173: ... 35 L 0 31 Imp qt 0 37 US qt Radiator capacity including all routes 1 32 L 1 16 Imp qt 1 40 US qt Air filter Wet element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 14 5 L 3 19 lmp gal 3 83 US gal Fuel reserve amount 4 5 L 0 99 lmp gal 1 19 US gal Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Model YFM45FXV U3C210 book Page 3 Tuesday June 21 2005 10 54 AM ...

Page 174: ...t Secondary reduction system Shaft drive Secondary reduction ratio 39 24 24 18 33 9 7 944 Transmission type V belt automatic Operation Left hand operation Forward gear 38 23 1 652 Reverse gear 29 17 1 706 Chassis Frame type Steel tube frame Caster angle 4 0 Trail 19 3 mm 0 76 in Tire Type Tubeless Model YFM45FXV U3C210 book Page 4 Tuesday June 21 2005 10 54 AM ...

Page 175: ...ion Double wishbone Rear suspension Swingarm Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 160 mm 6 30 in Rear wheel travel 180 mm 7 09 in Electrical Ignition system DC CDI Generator system AC magneto Battery type YTX20L BS Model YFM45FXV U3C210 book Page 5 Tuesday June 21 2005 10 54 AM ...

Page 176: ...r light LED Reverse indicator light LED Coolant temperature warning light LED Park indicator light LED Fuses Main fuse 30 A Headlight fuse 15 A Ignition fuse 10 A Auxiliary DC jack fuse 10 A Four wheel drive fuse 3 A Signaling system fuse 10 A Backup fuse 10 A Model YFM45FXV U3C210 book Page 6 Tuesday June 21 2005 10 54 AM ...

Page 177: ...ose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muf...

Page 178: ...e minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 07E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 300 800 80 6 2 500 1 600 160 12 5 000 3 200 320 18 7 500 4 800 480 24 10 000 6 400 640 30 12 500 8 000 800 36 15 000 9 600 960 42 17 500 11 200 1 120 48 20 000 12 800 1 ...

Page 179: ...EBU26310 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U3C210 book Page 1 Tuesday June 21 2005 10 54 AM ...

Page 180: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U3C210 book Page 2 Tuesday June 21 2005 10 54 AM ...

Page 181: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S U3C210 book Page 1 Tuesday June 21 2005 10 54 AM ...

Page 182: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U3C210 book Page 2 Tuesday June 21 2005 10 54 AM ...

Page 183: ...EBU00437 U3C210 book Page 3 Tuesday June 21 2005 10 54 AM ...

Page 184: ...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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