Yamaha YFM450FAT Owner'S Manual Download Page 168 | Manualshive

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4. Insert a new headlight bulb into the bulb

holder, and then secure the bulb by
hooking the tabs onto the bulb.

1. Do not touch the glass part of the bulb.

CAUTION:

_

Do not touch the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the luminos-
ity of the bulb, and the bulb life will be ad-
versely affected. Thoroughly clean off any
dirt and fingerprints on the headlight bulb
using a cloth moistened with alcohol or
thinner.

_

WARNING

POTENTIAL HAZARD
A headlight bulb is hot when it is on and
immediately after it is turned off.
WHAT CAN HAPPEN
You can be burned, or a fire could start
if the bulb touches something flamma-
ble.
HOW TO AVOID THE HAZARD
Wait for the bulb to cool before touching
or removing it.

U1D910.book Page 56 Thursday, May 27, 2004 11:08 AM

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Summary of Contents for YFM450FAT

Page 1: ......

Page 2: ......

Page 3: ...t safety information 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 regar...

Page 4: ...bol 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 inspectin...

Page 5: ...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 YF...

Page 6: ...ation number 3 2 Vehicle identification number 3 3 1 2 3 Indicator and warning lights 4 2 Fuel gauge 4 4 Speedometer unit 4 5 Handlebar switches 4 7 Throttle lever 4 13 Speed limiter 4 14 Front brake...

Page 7: ...ng a cold engine 6 1 Starting a warm engine 6 3 Parking on a slope 6 9 Accessories and loading 6 10 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful wh...

Page 8: ...8 34 V belt case drain plug 8 34 Spark arrester cleaning 8 35 Carburetor adjustment 8 36 Front brake pad check 8 39 Rear brake pad check 8 40 Inspecting the brake fluid level 8 41 Brake fluid replace...

Page 9: ...oubleshooting charts 8 61 CLEANING AND STORAGE 9 1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE 9 10...

Page 10: ...EBU00464 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS U1D910 book Page 1 Thursday May 27 2004 11 08 AM...

Page 11: ...fficult to read or comes off a replacement label is available from your Yamaha dealer 3 1 2 Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and...

Page 12: ...ever exceed the maximum rear cargo limit of 80kg 176 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4897 00 WARNING PULLING LOAD 4900 N 5 0 0 k g f 1102 l b f TONGUE WEI...

Page 13: ...this ATV if you are under the age of 16 increases your chance of severe injury or death Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distanc...

Page 14: ...t 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 tra...

Page 15: ...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 bot...

Page 16: ...the 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 uph...

Page 17: ...ure 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 mainta...

Page 18: ...ames or other sources of ignition such as the pilot 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 o...

Page 19: ...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 ve...

Page 20: ...oad adjusting ring 7 Brake pedal 8 V belt case 9 Radiator cap 10 Fuel cock 11 Air filter case 14 Engine oil dipstick 15 Oil filter cartridge 16 Coolant reservoir 17 V belt cooling duct check hose 18 R...

Page 21: ...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 numbe...

Page 22: ...icle 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 provi...

Page 23: ...9420 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...

Page 24: ...ck indicator light DIFF LOCK This indicator light and the differential gear lock indicator in the display come on when the differential gear lock switch is set to the 4WD LOCK position NOTE _ When the...

Page 25: ...ect lever is in the P park position EBU11312 Four wheel drive indicator This indicator comes on when the 2WD 4WD switch is set to the 4WD position The differential gear lock indicator DIFF LOCK in the...

Page 26: ...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 on may cause damage to the eng...

Page 27: ...utton 6 H button 7 M button The speedometer unit is equipped with the following a speedometer which shows the riding two tripmeters which show the distance traveled since they were last set to zero a...

Page 28: ...s information will enable you to plan future fuel stops NOTE _ Holding in the TRIP ODO button and then turning the key to ON switches the display between mph and km h _ Clock mode Pushing the button s...

Page 29: ...ery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it _ EBU12050 Engine stop switch Make sure that the engine stop sw...

Page 30: ...ls 1 Override switch OVERRIDE EBU13781 Override switch OVERRIDE Top speed is normally limited when operating in 4WD LOCK If conditions require more en gine power when riding forward push and hold this...

Page 31: ...TV is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the ATV The amount of effort is more the faster you go You may lose...

Page 32: ...ur wheel drive switch 2WD 4WD and a differential gear lock switch LOCK 4WD Four wheel drive 4WD Power is supplied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LO...

Page 33: ...ing from 2WD to 4WD or from 4WD to 4WD LOCK DIFF LOCK or vice versa while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD and in 4WD LOCK in some circumstances Changin...

Page 34: ...TENTIAL HAZARD Riding too fast while the ATV is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the ATV The amount of effo...

Page 35: ...mplete When the ATV is in 4WD LOCK the maximum traveling speed is limited to 35 km h 22 mph However if conditions require full engine power to be available push and hold the override switch to dis abl...

Page 36: ...ine pow er available and decreases the maximum speed of the ATV 1 Locknut 2 Adjusting screw a No more than 12 mm 0 47 in WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle c...

Page 37: ...er 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...

Page 38: ...ever The drive select lever is used to shift your ma chine into the low high neutral reverse and park positions Refer to page 6 4 for the drive select lever operation 1 Drive select lever U1D910 book...

Page 39: ...ut 1 Recoil starter WARNING POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position P WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cau...

Page 40: ...ll not flow Always turn the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position...

Page 41: ...1 Arrow mark pointing to OFF 1 Arrow mark pointing to RES OFF Position ON Position RES Position U1D910 book Page 19 Thursday May 27 2004 11 08 AM...

Page 42: ...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 EBU05670 Seat To remove the seat pull...

Page 43: ...page 4 20 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 b...

Page 44: ...1 Storage compartment EBU00582 Front carrier EBU00583 Rear carrier Maximum load limit 40 kg 88 lb Maximum load limit 80 kg 176 lb U1D910 book Page 22 Thursday May 27 2004 11 08 AM...

Page 45: ...ncrease the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring 2 Position indicator NOTE _ A...

Page 46: ...ment 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 sid...

Page 47: ...liary DC jack is not being used cover it with the cap CAUTION _ Do not use accessories requiring more than the above maximum capac ity This may overload the circuit and cause the fuse to blow If acces...

Page 48: ...1 Auxiliary DC jack EBU00112 U1D910 book Page 26 Thursday May 27 2004 11 08 AM...

Page 49: ...el level Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 6 8 12 8 17 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 7 8...

Page 50: ...d 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...

Page 51: ...are working properly If the brakes do not provide proper braking per formance inspect the brake pads for wear See pages 8 39 8 40 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT...

Page 52: ...gned 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 premi...

Page 53: ...AZARD 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...

Page 54: ...ke 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 17 8 20 for details If desired...

Page 55: ...s 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...

Page 56: ...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...

Page 57: ...could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 22 kPa 0 22 kgf cm2 3 2 psi Rear 22 kPa 0 22 kgf cm2 3 2 psi 4 Use no more than the follo...

Page 58: ...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 gaug...

Page 59: ...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 U1D910 book Page 11 Thursday May 27 2004 11 08 AM...

Page 60: ...iar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not und...

Page 61: ...o shift into neutral or park before starting the engine _ 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine star...

Page 62: ...If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it CAUTION _ See the Engine break in...

Page 63: ...Shifting Neutral to High and High to Low 1 Bring the ATV to a complete stop and re turn the throttle lever to the closed posi tion 2 Apply the brakes then shift by moving the drive select lever along...

Page 64: ...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 indic...

Page 65: ...roperly 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 obst...

Page 66: ...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 s...

Page 67: ...l 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 posi...

Page 68: ...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 transve...

Page 69: ...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 co...

Page 70: ...ng cargo and towing a trail er include the tongue weight in the maxi mum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the rear of the fro...

Page 71: ...hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHA...

Page 72: ...EBU15280 WARNING _ Indicates a potential hazard that could result in serious injury or death U1D910 book Page 13 Thursday May 27 2004 11 08 AM...

Page 73: ...7 1 Riding Your ATV U1D910 book Page 1 Thursday May 27 2004 11 08 AM...

Page 74: ...es of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers Riding...

Page 75: ...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...

Page 76: ...menda 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 shoul...

Page 77: ...N 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 t...

Page 78: ...cident 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 in...

Page 79: ...RD 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...

Page 80: ...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...

Page 81: ...m Turning in the adjusting screw limits the maximum engine power available and de creases the maximum speed of the ATV Turning the adjusting screw in decreases top speed and turning it out increases t...

Page 82: ...iler hitch Pulling load 500 kgf 1 102 lbf Total weight of trailer and cargo Tongue weight 15 kgf 33 lbf WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN H...

Page 83: ...ven 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 co...

Page 84: ...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...

Page 85: ...ause 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 accessorie...

Page 86: ...ARNING 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 dur...

Page 87: ...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 H...

Page 88: ...rating 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...

Page 89: ...ENTIAL 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...

Page 90: ...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...

Page 91: ...r 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...

Page 92: ...n riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling shift the drive select le ver to the low position L or the high position H Apply t...

Page 93: ...approach a curve slow down and be gin to turn the handlebars in the desired direc tion As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lea...

Page 94: ...proper 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 ov...

Page 95: ...tant 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 fo...

Page 96: ...s 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...

Page 97: ...NTIAL 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...

Page 98: ...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 U1D910 book Page 27 Th...

Page 99: ...by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake ped al will brake the wheels on t...

Page 100: ...shift to the parking position P 4WD or 4WD LOCK Apply both front and rear brakes gradually When fully stopped shift to the parking position P Dismount on uphill side or to a side if pointed straight u...

Page 101: ...also cause a loss of traction When this ATV is in 4WD or 4WD LOCK all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake wil...

Page 102: ...ng 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...

Page 103: ...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 HAZ...

Page 104: ...U1D910 book Page 33 Thursday May 27 2004 11 08 AM...

Page 105: ...ry 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 cont...

Page 106: ...d 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 check hose Also remove the...

Page 107: ...1 V belt cooling duct check hose left front side of ATV 1 Storage compartment check hose U1D910 book Page 36 Thursday May 27 2004 11 08 AM...

Page 108: ...l 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...

Page 109: ...eels 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...

Page 110: ...trol 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...

Page 111: ...f 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...

Page 112: ...ver 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 B...

Page 113: ...anual 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 th...

Page 114: ...ur 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 installatio...

Page 115: ...omes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Cooling system Check cool...

Page 116: ...if necessary Select lever safety system cable Check operation Adjust if necessary V belt Check operation Check for cracks or damage Wheels Check balance damage runout Repair if necessary Wheel bearin...

Page 117: ...e the oil seals every two years Replace the brake hoses every four years or if cracked or damaged WARNING _ Indicates a potential hazard that could result in serious injury or death Stabilizer bushes...

Page 118: ...need to be removed to perform some of the maintenance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 1 Panel A 2 Panel B 1 Panel C 2 Panel D 3 Pane...

Page 119: ...EBU00700 Panel A D To remove 1 Remove the seat 2 Pull outward on the areas shown and then pull upward U1D910 book Page 7 Thursday May 27 2004 11 08 AM...

Page 120: ...To install 1 Place the panel in its original position 2 Install the seat U1D910 book Page 8 Thursday May 27 2004 11 08 AM...

Page 121: ...position and in stall the bolt CAUTION _ When installing the panel be sure not to pinch the cables or wires _ EBU15370 Panel C To remove 1 Remove the top carrier bolts 1 Carrier bolt 4 top 2 Remove th...

Page 122: ...he quick fastener screws 2 Place the carrier in the original position and then install the carrier bolts under the fenders 3 Install the top carrier bolts and then tight en all bolts to the specified...

Page 123: ...and then take the panel off To install Place the panel in the original position and then install the bolts 1 Panel E 2 Bolt 3 EBU00638 Panel F To remove Pull outward on the areas shown 1 Panel F U1D91...

Page 124: ...specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Remove panel F See page 8 11 for panel removal and installation proce dures 2 Place the ATV on a level surfa...

Page 125: ...ween 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...

Page 126: ...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...

Page 127: ...g 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...

Page 128: ...se 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...

Page 129: ...necessary 14 Install panel F EBU15380 Final gear oil Checking the final gear oil level 1 Place the ATV on a level surface 2 Remove the oil filler bolt and then check the oil level in the final gear c...

Page 130: ...ear oil 1 Remove the engine guard and the final gear case guard by removing the bolts 1 Engine guard 2 Final gear case guard 3 Bolt 11 2 Place the ATV on a level surface 3 Place a container under the...

Page 131: ...ole CAUTION _ Be sure no foreign material enters the final gear case _ 7 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 23 Nm 2 3 m...

Page 132: ...el surface 2 Remove the differential gear oil filler bolt and check the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the recommend ed type to rais...

Page 133: ...ollect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil 1 Differential gear oil drain bolt 4 Install the differential gear oil drain bo...

Page 134: ...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 betwe...

Page 135: ...to the engine You may use soft water if you can not get distilled water _ NOTE _ If water is added have a Yamaha dealer check the antifreeze content of the cool ant as soon as possible The radiator fa...

Page 136: ...o prevent coolant from spilling on the foot rest 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 ste...

Page 137: ...emove the radiator cap 1 Radiator cap 6 Remove panel D See pages 8 7 8 8 for panel removal and installation proce dures 7 Remove the coolant reservoir cap 8 Disconnect the hose on the coolant res ervo...

Page 138: ...oir to the maximum level mark and then install the reservoir cap and panel D 13 Pour the recommended coolant into the radiator until it is full and then install the radiator cap Tightening torque Reco...

Page 139: ...ator If it is low add more coolant until it reaches the top of the radiator 15 Check for coolant leakage NOTE _ If any leakage is found have a Yamaha deal er check the cooling system _ 16 Install the...

Page 140: ...h side EBU00864 Spark plug inspection Removal 1 Remove panel A See pages 8 7 8 8 for panel removal and installation proce dures 2 Remove the spark plug cap 1 Spark plug cap U1D910 book Page 28 Thursda...

Page 141: ...ke the ATV to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes...

Page 142: ...ch is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as pos...

Page 143: ...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 20 4 21 1 Fastener 4 2 Air filte...

Page 144: ...ut of the air filter element and let it dry CAUTION _ Do not twist the air filter element when squeezing it _ WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filt...

Page 145: ...aned and lubri cated more often if the machine is operated in extremely dusty areas Each time the air filter element maintenance is performed check the air inlet to the filter case for obstructions Ch...

Page 146: ...ront side of ATV EBU08741 V belt case drain plug After riding in water deep enough to allow it to enter the V belt case remove this plug to drain the water from the case NOTE _ If water drains from th...

Page 147: ...r 1 Remove the bolts 2 Remove the tailpipe by pulling it out of the muffler 1 Bolt 3 2 Tailpipe 3 Tap the tailpipe lightly and then use a 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muf...

Page 148: ...ests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot...

Page 149: ...arm when it quickly responds to the throttle 2 Remove panel D See pages 8 7 8 8 for removal and installation procedures 3 Connect the tachometer to the spark plug lead and then set the idle to the spe...

Page 150: ...gularly This adjust ment however should be left to a professional Yamaha service technician EBU00307 Throttle lever adjustment NOTE Adjust the engine idling speed before adjust ing the throttle lever...

Page 151: ...e adjusted regu larly This adjustment however should be left to a Yamaha dealer EBU13090 Front brake pad check Check the brake pads for damage and wear If a brake pad thickness is less than 1 0 mm 0 0...

Page 152: ...t 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...

Page 153: ...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 f...

Page 154: ...lling 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 Hav...

Page 155: ...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 smooth...

Page 156: ...ut 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 a...

Page 157: ...roperly 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 tha...

Page 158: ...ke light switch as follows 1 Remove panel B See page 8 9 for pan el removal and installation procedures 2 Turn the adjusting nut while holding the rear brake light switch in place To make the brake li...

Page 159: ...8 9 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 Cabl...

Page 160: ...per and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun 1 Upper knuckle 2 Lower knuckle Recommended lubricant Lithium soap based grease U1D910 book Page 48 Thurs...

Page 161: ...4 Remove the wheel 1 Nut 4 EBU11211 Wheel installation 1 Install the wheel and the nuts NOTE _ The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used fo...

Page 162: ...sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the bat tery If the battery seems to have discharged consult a Yamaha dealer 1 Negative battery ter...

Page 163: ...RD 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...

Page 164: ...Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU08762 Fuse replacement 1 The main fuse...

Page 165: ...use 3 Auxiliary DC jack fuse 4 Four wheel drive fuse 5 Signaling system fuse 6 Backup fuse for odometer and clock 7 Spare fuse 3 Specified fuses Main fuse 30 0A Headlight fuse 15 0A Ignition fuse 10 0...

Page 166: ...bulb holder cover at the rear of the headlight by pulling it off 1 Headlight bulb holder cover WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the...

Page 167: ...t bulb holder by turning it counterclockwise 1 Headlight bulb holder 3 Remove the defective bulb by unhooking the headlight bulb holder tabs 1 Headlight bulb holder tab 2 U1D910 book Page 55 Thursday...

Page 168: ...ss the luminos ity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb WARNING POTENTIAL HAZARD A headlight bulb is hot when...

Page 169: ...at the rear of the headlight EBU01089 Headlight beam adjustment CAUTION _ It is advisable to have a Yamaha dealer make this adjustment _ To raise the beam turn the adjusting screw in direction a To lo...

Page 170: ...ght unit 2 Nut 2 2 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Tail brake light unit 2 Tail brake light bulb holder 3 Remove the defective bulb from the bulb holder...

Page 171: ...m in the fuel compression or ignition sys tems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repai...

Page 172: ...EN 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 incl...

Page 173: ...he 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 W...

Page 174: ...er 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 Leve...

Page 175: ...les 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 tr...

Page 176: ...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 m...

Page 177: ...blespoon 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 Lu...

Page 178: ...ry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machin...

Page 179: ...1 233 mm 48 5 in Ground clearance 245 mm 9 65 in Minimum turning radius 3 000 mm 118 1 in Basic weight With oil and full fuel tank 285 0 kg 628 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylind...

Page 180: ...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 oi...

Page 181: ...L 0 20 Imp qt 0 24 US qt Radiator capacity including all routes 1 30 L 1 14 Imp qt 1 37 US qt Air filter Wet type element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 15 0 L 3 30 lmp gal 3 96 U...

Page 182: ...ry reduction system Shaft drive Secondary reduction ratio 39 24 24 18 33 9 7 944 Transmission type V belt automatic Operation Left hand operation Reverse gear 29 17 1 706 Sub transmission ratio low 45...

Page 183: ...le wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 160 0 mm 6 30 in Rear...

Page 184: ...mperature warning light LED Park indicator light LED High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Fuses Main fuse 30 0 A Headlight fuse 15 0...

Page 185: ...se 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 inoper...

Page 186: ...minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 06E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month...

Page 187: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U1D910 book Page 1 Thursday May 27 2004 11 08 AM...

Page 188: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U1D910 book Page 2 Thursday May 27 2004 11 08 AM...

Page 189: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S U1D910 book Page 1 Thursday May 27 2004 11 08 AM...

Page 190: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U1D910 book Page 2 Thursday May 27 2004 11 08 AM...

Page 191: ...EBU00437 U1D910 book Page 3 Thursday May 27 2004 11 08 AM...

Page 192: ...EBU00438...

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