Yamaha YFM450FAZ Owner'S Manual Download | Manualshive

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8

EBU28413

Checking the front brake pads and rear
brake friction plates

The front brake pads and the rear brake friction
plates must be checked for wear at the intervals
specified in the periodic maintenance and lubrica-
tion chart.

TIP

This ATV is equipped with a wet, multiple-disc type
rear brake, which is located inside of the final gear
case.

EBU24171

Front brake pads

Check each front brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-
aged or if the lining thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer replace the brake
pads as a set.

TIP

The wheels need to be removed to check the
brake pads. (See page 8-59.)

EBU28421

Rear brake friction plates

The rear brake is provided with a wear indicator,
which allows you to check the brake friction plate
wear without having to disassemble the brake. To
check the brake friction plate wear, check the posi-
tion of the wear indicator while applying the brake.
If a brake friction plate has worn to the point that

1. Lining thickness

U37S61E0.book Page 39 Tuesday, June 2, 2009 10:33 AM

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Summary of Contents for YFM450FAZ

Page 1: ...UAL DEL PROPIETARIO 37S F8199 61 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad DIC183 ...

Page 2: ...PRINTED IN USA 2009 06 0 3 1 CR E F S YAMAHA MOTOR CO LTD DIC183 ...

Page 3: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL YFM45FGZ YFM45FGHZ YFM450FAZ 37S F8199 61 E0 U37S61E0 book Page 1 Tuesday June 2 2009 10 33 AM ...

Page 4: ...nlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Shinya Shimada Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 98 37 EC 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title an...

Page 5: ...tanding of the features and operation of this ATV This manual includes important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manua...

Page 6: ... safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key info...

Page 7: ...motorway Please check your local riding laws and regulations before operating this ATV EBU17410 YFM45FGZ YFM45FGHZ YFM450FAZ OWNER S MANUAL 2009 by Yamaha Motor Co Ltd 1st edition May 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A U37S61E0 book Page 1 Tuesday June 2 2009 10 33 AM ...

Page 8: ...ke lever 4 12 Brake pedal and rear brake lever 4 12 Drive select lever 4 13 Recoil starter 4 13 Fuel tank cap 4 14 Fuel 4 14 Fuel cock 4 16 Starter choke 4 17 Seat 4 18 Storage compartments 4 19 Front carrier 4 21 Rear carrier 4 21 Adjusting the front and rear shock absorber assemblies 4 21 Auxiliary DC jack 4 23 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Differential gear...

Page 9: ...s manual and tool kit 8 1 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing panels 8 9 Checking the spark plug 8 14 Engine oil and oil filter cartridge 8 17 Final gear oil 8 21 Differential gear oil 8 24 Coolant 8 26 Cleaning the air filter element 8 30 Cleaning the spark arrester 8 33 V belt cooling duct check hose...

Page 10: ...hub bearings 8 49 Lubricating the drive shaft universal joint 8 49 Checking the stabilizer bushes 8 50 Lubricating the rear knuckle pivots 8 50 Lubricating the steering shaft 8 50 Battery 8 51 Replacing a fuse 8 53 Replacing a headlight bulb 8 55 Adjusting a headlight beam 8 57 Replacing the tail brake light bulb 8 57 Removing a wheel 8 59 Installing a wheel 8 59 Troubleshooting 8 61 Troubleshooti...

Page 11: ...abels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer For Europe 6 7 8 11 9 10 U37S61E0 book Page 1 Tuesday June 2 2009 10 33 AM ...

Page 12: ...bs 25 0 kPa 0 25 kgf cm 3 6 psi 25 0 kPa 0 25 kgf cm 3 6 psi 5FU F816M M0 1P0 F816P 20 37S F817R 10 80 kg 176 lbs 5880 N 600 kgf 1322 lbf 147 N 15 kgf 33 lbf 37S F817S 00 1 3 2 4 5 U37S61E0 book Page 2 Tuesday June 2 2009 10 33 AM ...

Page 13: ...1 3 1 1P0 F816R 00 1P0 F816L 20 6 7 8 U37S61E0 book Page 3 Tuesday June 2 2009 10 33 AM ...

Page 14: ...g 1 lb 37S F816S 00 YEAR OF CONSTRUCTION 2009 MODEL YFM450FWAN MAX POWER 19 4 kW MASS IN RUNNING ORDER 285 kg YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN 37S F155A 10 9 10 11 U37S61E0 book Page 4 Tuesday June 2 2009 10 33 AM ...

Page 15: ... children under age 10 to operate this ATV Operation of this ATV by children under the age of 10 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 12 to operate this ATV Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 1...

Page 16: ...ath Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all ...

Page 17: ...r Overloading can cause loss of control Loss of control can result in severe injury or death This pictogram shows trailer Hitch Tongue weight limit Weight on the trailer tongue Overloading can cause loss of control Loss of control can result in severe injury or death U37S61E0 book Page 7 Tuesday June 2 2009 10 33 AM ...

Page 18: ...1 8 1 For Oceania 6 7 8 9 U37S61E0 book Page 8 Tuesday June 2 2009 10 33 AM ...

Page 19: ...1 9 1 5880 N 1322 600 kgf 15 kgf 37S F151K 00 5FU F816M 20 25 kPa 3 6 psi 25 kPa 3 6 psi 22 kPa 3 2 psi 22 kPa 3 2 psi 1 3 4 5 2 U37S61E0 book Page 9 Tuesday June 2 2009 10 33 AM ...

Page 20: ...1 10 1 16 UNDER 1P0 F816L 00 7 6 U37S61E0 book Page 10 Tuesday June 2 2009 10 33 AM ...

Page 21: ...an be a fire or explosion hazard To avoid injury or death never store fuel or flammable liquids in this storage compartment Storage should not exceed 0 5 kg 1 lb 37S F151F 00 8 9 U37S61E0 book Page 11 Tuesday June 2 2009 10 33 AM ...

Page 22: ...child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Watch carefully for other vehicles when operat ing on unpaved public streets or roads Make sure you know your country s ...

Page 23: ...imbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully...

Page 24: ...ed stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse 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 de scribed in this manual Never...

Page 25: ...ne exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors WARNING EWB02591 When transporting the ATV in another vehicle be sure it is kept...

Page 26: ... cap 10 Oil filter cartridge 11 Coolant reservoir 12 V belt cooling duct check hose 1 Rear shock absorber assembly spring preload adjusting ring 2 Spark arrester 3 Rear storage compartment and tool kit 4 Spark plug 5 Front shock absorber assembly spring preload adjusting ring 6 Rear brake light switch 7 Brake pedal 8 V belt case drain plug 1 2 3 4 5 6 7 8 U37S61E0 book Page 1 Tuesday June 2 2009 1...

Page 27: ...Handlebar switches 3 Starter choke 4 Horn switch 5 Drive select lever 6 Multi function display 7 Main switch 8 Auxiliary DC jack 9 Fuel tank cap 10 On Command four wheel drive differential gear lock switch 11 Throttle lever 12 Front brake lever 13 Front storage compartment 9 5 4 13 12 11 10 2 3 6 7 8 U37S61E0 book Page 2 Tuesday June 2 2009 10 33 AM ...

Page 28: ...e as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U37S61E0 book Page 1 Tuesday June 2 2009 10 33 AM ...

Page 29: ... is in the neutral position EBU17920 Coolant temperature warning light This warning light comes on when the engine over heats When this occurs during operation stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes NOTICE ECB00010 The engine may overheat if the ATV is over loaded In this case reduce the load to spec ification 1 On Command differential gear lo...

Page 30: ...nism in the dif ferential gear case the four wheel drive indica tor may not come on until the ATV starts moving When the On Command differential gear lock switch is set to LOCK the indicator and the indicator light DIFF LOCK will flash until the differential gear is locked If the indicator and the indicator light continue to flash the differen tial is not locked In this case start moving to al low...

Page 31: ...pushing the TRIP ODO button and then push the TRIP ODO button for at least three seconds The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel This in formation will enable you to plan future fuel stops TIP Pushing and holding in the TRIP ODO button and turning the key to ON while the button is pushed switches the display between mph and km h Clock mode ...

Page 32: ... indicates the amount of fuel in the fuel tank When the needle reaches the red line re fill the tank at the first opportunity TIP If the ATV runs out of fuel move the fuel cock lever to the RES position Approximately 4 5 L 1 19 US gal 0 99 Imp gal of fuel will be remaining in the tank EBU18061 Handlebar switches 1 Fuel gauge 2 Red line 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Overr...

Page 33: ...the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00041 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 51 for battery charging in...

Page 34: ...rential gear lock and al low extra time and distance for maneuvers All wheels turn at the same speed when the dif ferential is locked so it takes more effort to turn the ATV The effort needed to turn increas es with the riding speed You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are trav eling EBU26606 On Command four wheel drive switch 2WD 4WD W...

Page 35: ...the 4WD position Then the four wheel drive indicator comes on in the multi function dis play To change from four wheel drive to two wheel drive stop the ATV and push the switch in to the 2WD position EBU18255 On Command differential gear lock switch 4WD LOCK WARNING EWB00131 Always stop the ATV before changing from four wheel drive to four wheel drive differen tial gear lock or vice versa The ATV ...

Page 36: ...This ATV is equipped with a switch allowing you to lock the differential gear when in four wheel drive Select the appropriate switch position according to the terrain and the conditions 4WD four wheel drive Power is supplied to the rear and front wheels LOCK four wheel drive with the differential gear locked Power is supplied to the rear and front wheels and the differential gear is locked Unlike ...

Page 37: ...ential gear lock stop the ATV and push the switch to the 4WD position TIP When the switch is set to LOCK the differential gear lock indicator and indicator light will flash until the differential gear is locked When the indicator and indicator light are flash ing turning the handlebar back and forth will help the differential gear lock to engage 1 Differential gear lock lever 2 On Command four whe...

Page 38: ...ver will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time the throttle lever is re leased Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released EBU1...

Page 39: ...ttle operation You could lose control resulting in an accident EWB00241 3 Tighten the locknut EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull the brake lever toward the handlebar grip EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left hand...

Page 40: ... drive select lever and driving in reverse section on page 6 3 for the drive select lever operation EBU18690 Recoil starter Firmly grasp the handle and pull slightly until en gagement can be felt Then pull forcefully being careful not to pull the rope all the way out 1 Brake pedal 1 Rear brake lever 1 Drive select lever U37S61E0 book Page 13 Tuesday June 2 2009 10 33 AM ...

Page 41: ... EBU18754 Fuel Make sure there is sufficient gasoline in the tank WARNING EWB02521 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling fol low these instructions 1 Before refueling turn off the engine and be sure that no one is sitting on the vehicle Nev er refuel while smoking or while in the vicinity 1 Recoil starter ...

Page 42: ...cloth since fuel may deteriorate painted surfaces or plastic parts ECB00981 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed WARNING EWB02531 Gasoline is poisonous and can cause injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your 1 Maximum...

Page 43: ... a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand Use of un leaded fuel will extend spark plug life and reduce maintenance costs EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations OFF With the fuel coc...

Page 44: ...rn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke 1 Arrow mark pointing to ON 1 Arrow mark ...

Page 45: ...81 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear Make sure that the seat is securely fitted 1 Starter choke 1 Seat 2 Seat lock lever U37S61E0 book Page 18 Tuesday June 2 2009 10 33 AM ...

Page 46: ...ey must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartments The front storage compartment is located at the front right side of the ATV To access the storage compartment remove the storage compartment cover by turning it counterclockwise 1 Projection 2 Seat holder 1 Front storage compartment cover U37S61E0 book Page 19 Tuesday June 2 2009 10 33 AM ...

Page 47: ... lb for the front storage compartment or 2 0 kg 4 lb for the rear storage compartment Do not exceed the maximum load of 210 0 kg 463 lb for the ATV TIP A drain plug is fitted at the bottom of the front stor age compartment and there is a check hose at the bottom of the rear storage compartment If any water collects in a storage compartment re move the drain plug or the check hose drain the water a...

Page 48: ...463 lb for the ATV EBU19145 Adjusting the front and rear shock ab sorber assemblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions WARNING EWB00400 Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac cident 1 Storage compartment ...

Page 49: ...pension and in direction b to de crease the spring preload and thereby soften the suspension TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 U37S61E0 book Page 22 Tuesday June 2 2009 10 33 AM ...

Page 50: ...liary DC jack is not being used cover it with the cap NOTICE ECB00120 Do not use accessories requiring more than the above maximum capacity This may overload the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine start ing may become difficult Do not use an automotive cigarette lighter o...

Page 51: ... a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 14 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 17 Final gear oil Check ATV for o...

Page 52: ...ble free play and adjust if necessary 5 4 8 37 Control cables Make sure that operation is smooth Lubricate if necessary 8 47 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 48 Brake levers Ma...

Page 53: ...8 26 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU28531 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front brake lever If there is free play have a Yamaha dealer check the brake system Check for correct free play in the rear brake lever and brake pedal If the free play is incorrect ad just i...

Page 54: ...the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19814 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use the low pressure tire gauge to check and ad just tire pressures when the tires are cold Tire pressures...

Page 55: ...n the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended tire pressure Front 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum tire pressure Front 22 0 kPa 0 220 kgf cm 3 2 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi 1 Low pressure tire gauge U37S61E0 book Page...

Page 56: ...rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate 1 Tire wear limit Front Manufacturer model YFM450FAZ CHENG SHIN C 828 YFM45FGHZ MAXXIS M979 YFM45FGZ MAXXIS M979 Size AT25 x 8 12 Type Tubeless Rear Manufacturer model Y...

Page 57: ...sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary U37S61E0 book Page 7 Tuesday June 2 2009 10 33 AM ...

Page 58: ...h to 3 Shift the drive select lever into the neutral or park position The corresponding indicator light should come on If the indicator light does not come on have a Yamaha dealer check the electrical circuit TIP The engine can be started under the following con ditions The drive select lever is in the neutral or park po sition The rear brake lever is applied with the drive se lect lever in any po...

Page 59: ...ngine more than 10 sec onds on each attempt If the battery is discharged pull the recoil starter to start the engine 7 If the engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine 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 ...

Page 60: ... range 1 Bring the ATV to a complete stop 2 Apply the brake pedal and then shift by mov ing the drive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted into position 3 Release the brake pedal and then open the throttle lever gradually Shifting Neutral to Reverse and Reverse to Park WARNING EWB00720 Improper operation in reverse could make you hit an...

Page 61: ...m reverse to park and vice versa by moving the drive select lever along the shift guide TIP When in reverse the reverse indicator light should come on If the indicator light does not come on have a Yamaha dealer check the elec trical circuit Due to the synchronizing mechanism in the en gine the indicator light may not come on until the ATV starts moving 1 Drive select lever 2 L Low range 3 H High ...

Page 62: ...gine wear and polish themselves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided 0 160 km 0 100 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 160 320 km 100 200 mi or 10 20 hours Avoid p...

Page 63: ...plying the brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to the park position EBU20910 Accessories and loading EBU20921 Genuine Yamaha Accessories Choosing accessories for your ATV is an important decision Genuine Yamaha Accessories which are available only from a Yamaha dealer have been designed tested and approved by Yamaha for use on your ATV Many companie...

Page 64: ...le you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when rid...

Page 65: ...with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trail er Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow s...

Page 66: ...7 1 7 EBU21141 RIDING YOUR ATV U37S61E0 book Page 1 Tuesday June 2 2009 10 33 AM ...

Page 67: ... and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 4 Also read all warning and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01381 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increased if the operat...

Page 68: ...390 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WAR...

Page 69: ...G Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating wi...

Page 70: ...ach time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual WARNING Failure to inspect the ATV before operating it and to maintain it prop erly increases the possibility of an accident or equipment damage EWB01431 Speed limiter For r...

Page 71: ...side to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier vehicle takes long...

Page 72: ...ll 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 EWB01471 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 210 0 kg 463 l...

Page 73: ...the engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine ...

Page 74: ...faces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01511 While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles Watch carefully for other vehicles Make sure you U37S61E0 boo...

Page 75: ...ch may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01531 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary t...

Page 76: ...on flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where you cannot easily be seen Mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles EWB01551 Do not ride in areas posted no trespassing Do not ride on private property without getting per mission U37S61E0 book Page 11 Tu...

Page 77: ...release the throt tle and apply the brakes smoothly and evenly Im proper use of the brakes can cause the tires to lose traction reducing control and increasing the possi bility of an accident NOTICE ECB00251 Do not shift from low range to high range or vice versa without coming to a complete stop Damage to the engine or drive train may occur TURNING YOUR ATV WARNING EWB01771 Always follow proper p...

Page 78: ...f your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments 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...

Page 79: ...suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a...

Page 80: ...u are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to los...

Page 81: ...mely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble Improper braking can cause the wheels on the uphill side to come off the ground or cause loss of traction Apply brakes gr...

Page 82: ...ther the front or rear brake be cause the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01632 I...

Page 83: ...t may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill 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 obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel CR...

Page 84: ...h out verifying that you have regained proper braking ability WARNING Wet brakes may have re duced stopping ability which could cause loss of control EWB02621 After riding your ATV in water be sure to drain the trapped 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 rear storage compartment check...

Page 85: ...n operat ed in salt water or muddy conditions 1 Air filter case check hose 1 V belt cooling duct check hose left front side of ATV 1 Drive select lever box check hose 1 Storage compartment check hose U37S61E0 book Page 20 Tuesday June 2 2009 10 33 AM ...

Page 86: ...in should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult SLIDING AND SKIDDING WARNING EWB01662 Skidding or sliding improperly may cause you to lose control of this ATV You may also...

Page 87: ...tioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrai...

Page 88: ...trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 13 If your ATV is traversing a sloping surface Be sure to ride with your weight p...

Page 89: ...ainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more information about carbon monoxide The intervals given in the periodic maintenance and l...

Page 90: ...ntenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s manual 2 Owner s tool kit 3 Low pressure tire gauge U37S61E0 book Page 2 Tuesday June 2 2009 10 33 AM ...

Page 91: ...ire special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust ...

Page 92: ...ess and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U37S61E0 book Page 4 Tuesday June 2 2009 10 33 AM ...

Page 93: ...ata and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check operation and correct if necessary Check fluid level and ATV for fluid leakage and corre...

Page 94: ...is fasteners Make sure that all nuts bolts and screws are properly tightened 11 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 12 Stabilizer bushes Check for cracks or other damage and replace if necessary 13 Rear knuckle pivots Lubricate with lithium soap based grease 14 Steering shaft Lubricate with lithium soap based grease 15 ...

Page 95: ...rect if neces sary 22 Final gear oil Change Check ATV for oil leakage and correct if neces sary 23 Cooling system Check coolant level and ATV for coolant leakage and correct if necessary Replace coolant Every 2 years 24 Moving parts and cables Lubricate 25 Drive select lever safety system cable Check operation and adjust or replace if neces sary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Which...

Page 96: ...our years and if cracked or damaged 26 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 27 Front and rear brake switches Check operation and correct if necessary 28 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENAN...

Page 97: ... chapter Refer to this section each time a panel needs to be removed and installed EBU27601 Panels A and D To remove one of the panels 1 Remove the seat See page 4 18 2 Pull outward on the areas shown and then pull upward as shown 1 Panel A 2 Panel B 1 Panel C 2 Panel D 3 Panel E 4 Panel F U37S61E0 book Page 9 Tuesday June 2 2009 10 33 AM ...

Page 98: ...8 10 8 To install one of the panels 1 Place the panel in its original position U37S61E0 book Page 10 Tuesday June 2 2009 10 33 AM ...

Page 99: ...off To install the panel Place the panel in the original position and install the bolt NOTICE When installing the panel be sure not to pinch the cables or wires ECB00381 Panel C To remove the panel 1 Remove the carrier top bolts 1 Panel B 2 Bolt U37S61E0 book Page 11 Tuesday June 2 2009 10 33 AM ...

Page 100: ...under the fenders and then take the carrier off 3 Remove the quick fastener screws and then pull the panel upward to remove it 1 Carrier bolt top 1 1 1 1 Carrier bolt under the fenders U37S61E0 book Page 12 Tuesday June 2 2009 10 33 AM ...

Page 101: ... under the fenders 3 Install the carrier top bolts and then tighten all bolts to the specified torques Panel E To remove the panel Remove the bolts and then take the panel off 1 Quick fastener screw 2 Panel C 1 2 Tightening torques Carrier bolt top 34 Nm 3 4 m kgf 24 ft lbf Carrier bolt under fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Panel E 2 Bolt U37S61E0 book Page 13 Tuesday June 2 2009 10 33 AM ...

Page 102: ... is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove panel A See page 8 9 2 Remove the spark plug ca...

Page 103: ...electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally TIP If the spark plug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 1 Spark plug cap 1 Spark plug wrench U37S61E0 book Page 15 Tuesday June 2 2009 10 33 AM ...

Page 104: ...s 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque TIP If a torque wrench is not available when installing the spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 3 Install the spark plug cap 4 Install the panel Specified spark plug NG...

Page 105: ...ine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil set tles for an accurate reading 4 Remove the engine oil filler cap and then wipe the engine oil dipstick off with a clean rag 5 Insert the dipstick into the filler hole without screwing it in and then remove it again...

Page 106: ...all the panel To change the engine oil with or without oil fil ter cartridge replacement 1 Place the ATV on a level surface 2 Remove panel F See page 8 9 3 Start the engine warm it up for several min utes and then turn it off 4 Place an oil pan under the engine to collect the used oil 5 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase ...

Page 107: ...page 8 9 7 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer 8 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge 1 Oil filter cartridge 1 Oil filter wrench U37S61E0 book Page 19 Tuesday June 2 2009 10 33 AM ...

Page 108: ...pecified torque with a torque wrench 10 Install panels E and D 11 Install the engine oil drain bolt and then tight en it to the specified torque 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf U37S61E0 book Page 20 Tuesday June 2 2009 10 33 AM ...

Page 109: ...s leaking immediately turn the engine off and check for the cause 14 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 15 Install panel F EBU28573 Final gear oil The final gear case must be checked for oil leak age before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In ad dition the final gear oil level must be...

Page 110: ...change the final gear oil 1 Place the ATV on a level surface 2 Remove the engine guard and the final gear case guard by removing the bolts 3 Place an oil pan under the final gear case to collect the used oil 4 Remove the final gear oil filler bolt and the fi nal gear oil drain bolt to drain the oil from the final gear case 1 Final gear oil filler bolt 2 Correct oil level 3 Final gear oil Tightenin...

Page 111: ...E80W 90 API GL 5 Hypoid gear oil may be used instead However when using this oil noise from the final gear case may occur when applying the rear brake 7 Install the oil filler bolt and then tighten it to the specified torque 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 24 Nm 2 4 m kgf 17 ft lbf 1 Final gear oil filler bolt 2 Correct oil level 3 Final gear oil Recommended...

Page 112: ... tervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface TIP The differential gear oil level must be checked when the engine is cold 2 Remove the differential gear oil filler bolt and then check the oil level in the differential gear case The oil level should be at the brim of the filler hole Tightening torque ...

Page 113: ...oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case 4 Install the drain bolt and then tighten it to the specified torque 5 Refill with the recommended differential gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material en ters the differential gear case ECB00411 Tightening torque Differential gear oil filler bolt 23...

Page 114: ...rt EBU27124 To check the coolant level 1 Place the ATV on a level surface TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser voir TIP The coolant should be between the minimum and maximum level marks 1 Differential gear oil 2 Differential gear oil filler bolt 3 Correct oil level Recommended differen...

Page 115: ...sion If water has been added to the coolant have a Yamaha dealer check the antifreeze con tent of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECB01011 TIP The radiator fan is automatically switched on or off according to the coolant temperature in the radiator If the engine overheats see page 8 62 for fur ther instructions EBU23603 To change the coola...

Page 116: ...surface 2 Remove panels E and F See page 8 9 3 Place a container under the engine and then remove the coolant drain bolt Use a trough or a similar object as shown to prevent coolant from spilling on the footrest 4 Remove the front carrier and panel C See page 8 9 5 Remove the radiator cap 1 Coolant drain bolt 1 Trough U37S61E0 book Page 28 Tuesday June 2 2009 10 33 AM ...

Page 117: ...p water 10 Replace the coolant drain bolt washer if it is damaged install the coolant drain bolt and then tighten it to the specified torque 11 Connect the coolant reservoir hose 12 Pour the recommended coolant into the reser voir to the maximum level mark and then in stall the reservoir cap NOTICE Mix 1 Radiator cap 1 Coolant reservoir hose Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 2...

Page 118: ... system 17 Install the panels and the front carrier EBU23646 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean or if necessary replace the air filter element more frequently if you are riding in unusually wet or dusty areas TIP There is a check hose at the bottom of the air filter case If dus...

Page 119: ... 3 Remove the air filter case cover by unhooking the air filter case cover holders 4 Pull the air filter element out of the air filter case 1 Air filter case check hose 1 Air filter case cover holder 2 Air filter case cover U37S61E0 book Page 31 Tuesday June 2 2009 10 33 AM ...

Page 120: ...e sponge material Never use low flash point sol vents or gasoline to clean the sponge ma terial because the engine could catch fire or explode EWB01941 7 Squeeze the excess solvent out of the sponge material and let it dry NOTICE Do not twist the sponge material when squeezing it ECB00441 1 Air filter element 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate U37S61E0 boo...

Page 121: ... possible engine damage Additionally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating ECB00461 12 Install the seat TIP The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maint...

Page 122: ...spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the bolts and tighten them to the speci fied torque 1 Bolt 2 Tailpipe 1 Tailpipe 2 Spark arrester Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf U37S61E0 book Page 34 Tuesday June 2 2009 10 33 AM ...

Page 123: ...dust or water collects in the V belt cooling duct check hose remove the hose and clean it EBU23930 V belt case drain plug After riding in water deep enough to allow it to en ter the V belt case remove this plug to drain the water from the case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the water may affect other engine parts 1 V belt cool...

Page 124: ...thout sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24010 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart TIP A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it up TIP The en...

Page 125: ... mm 0 12 0 20 in at the throttle lever Period ically check the throttle cable free play and if nec essary adjust it as follows TIP The engine idling speed must be checked and ad justed if necessary before adjusting the throttle ca ble free play 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle cable free play turn the throttle cable free play adjusting bolt in di rectio...

Page 126: ...er safety system cable stretch es with use which can result in improper function Therefore the safety system cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EBU29601 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be per formed by a Yamaha dealer WARNING EWB02571 Operat...

Page 127: ...ining thickness If a brake pad is dam aged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set TIP The wheels need to be removed to check the brake pads See page 8 59 EBU28421 Rear brake friction plates The rear brake is provided with a wear indicator which allows you to check the brake friction plate wear without having to disassemble the br...

Page 128: ...low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing le...

Page 129: ...use EBU24281 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart In addition have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are dam aged or leaking Oil seals Replace every two years Brake hoses R...

Page 130: ...ng the rear brake be sure to adjust both the brake pedal and the brake lever Before adjusting the brake lever and brake pedal free play check the rear brake friction plates for wear Adjusting the brake pedal and brake lever free play The brake pedal free play should measure 17 0 20 0 mm 0 67 0 79 in The brake lever free play should measure 8 0 10 5 mm 0 31 0 41 in If ei ther free play is incorrect...

Page 131: ... a until it stops apply approximately 50 N 5 0 kgf 11 2 lbf of force and then turn the brake pedal free play adjusting nut on the brake ca ble at the final gear case so that gap A mea sures 2 5 3 0 mm 0 10 0 12 in 1 Locknut 2 Brake lever free play adjusting bolt 1 Brake lever free play adjusting nut U37S61E0 book Page 43 Tuesday June 2 2009 10 33 AM ...

Page 132: ... 16 0 24 in 5 Check the brake lever free play and if neces sary adjust it by turning the brake lever free play adjusting bolt at the brake lever Turn the brake lever free play adjusting bolt in direction a to increase the free play and in direction b to decrease it 1 Brake pedal free play adjusting nut 2 Brake camshaft lever 3 Gap A 1 Brake lever free play adjusting nut 2 Brake camshaft lever 3 Ga...

Page 133: ... in above the footboard If the brake pedal position is incorrect have a Yamaha dealer adjust it EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them re placed by a Yamaha dealer 1 Locknut 2 Brake lever free play adjusting bolt 1 Distance be...

Page 134: ...nt brake light switch should be adjusted by a Yamaha dealer 1 Remove panel B See page 8 9 2 Turn the brake light switch adjusting nut while holding the 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 adjusting nut in direction b 1 Front axle boot each side 1 Rear axle boot each side 1 1 U37S61E...

Page 135: ...ayed or kinked which could restrict the operation of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an acci dent or collision EBU28711 Checking and lubricating the front and rear brake levers The op...

Page 136: ...ecked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel B See page 8 9 Recommended lubricants Front brake lever Silicone grease Rear brake lever Lithium soap based grease Recommended lubricant Lithium soap based grease U37S61E0 book Page 48 Tuesday June 2 2009 10 33 AM ...

Page 137: ... if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU24970 Lubricating the drive shaft universal joint The drive shaft universal joint must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the universal joint using a grease gun Recommended lubricant Lithium soap based grease U37S61E0 book Page 49 Tuesday June 2...

Page 138: ...ear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the pivoting points using a grease gun EBU25103 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease 1 Grease nippl...

Page 139: ...th water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN To r...

Page 140: ... damage the battery If you do not have access to a constant voltage battery charger have a Yamaha dealer charge your battery To store the battery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB...

Page 141: ...egative battery lead by installing their bolt 3 Install the battery holding plate by installing the bolts 4 Install the seat See page 4 18 EBU25326 Replacing a fuse The main fuse and the fuse box are located under the seat See page 4 18 1 Positive battery lead red 2 Negative battery lead black 1 2 1 Main fuse 2 Fuse box U37S61E0 book Page 53 Tuesday June 2 2009 10 33 AM ...

Page 142: ...nt accidental short circuiting turn off the main switch when checking or replacing a fuse 1 Main fuse 2 Spare main fuse 1 Headlight fuse 2 Ignition fuse 3 Auxiliary DC jack fuse 4 Four wheel drive motor fuse 5 Signaling system fuse 6 Backup fuse for odometer and clock 7 Spare fuse U37S61E0 book Page 54 Tuesday June 2 2009 10 33 AM ...

Page 143: ...devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25481 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the headlight bulb holder cover by pulling it off Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Four whe...

Page 144: ... it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth moistened with alcohol or thinner ECB00651 6 Install the bulb holder by pushing it in and turn ing it clockwise 1 Headlight bulb holder cover 1 Headlight bulb holder 1 Do not touch the g...

Page 145: ...0690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25621 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the tail brake light assembly by re moving the nuts together with the wa...

Page 146: ...lb by turning it counterclockwise 3 Remove the burnt out bulb by pushing it in and turning it counterclockwise 1 Tail brake light assembly 2 Nut 1 Tail brake light assembly 2 Tail brake light bulb holder U37S61E0 book Page 58 Tuesday June 2 2009 10 33 AM ...

Page 147: ...wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU25701 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP The arrow mark on the tire must point toward the rotating direction of the wheel 1 Tail brake light bulb holder 2 Tail bra...

Page 148: ...tapered side to wards the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U37S61E0 book Page 60 Tuesday June 2 2009 10 33 AM ...

Page 149: ...ny repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or...

Page 150: ...TV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is goo...

Page 151: ... can be temporarily used instead provided that it is changed to the rec ommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If the engine overheats ...

Page 152: ...on dry out the linings EWB02311 NOTICE Excessive water pressure may cause water seepage and deteriora tion of wheel bearings brakes transmis sion seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applica tions such as those available in coin oper ated car washers ECB00711 4 Once most of the dirt has been hosed off wash all surfaces with wa...

Page 153: ...f available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparki...

Page 154: ...rom entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery see page 8 51 TIP Make any necessary repairs before storing the ATV U37S61E0 book Page 3 Tuesday June 2 2009 10 33 AM ...

Page 155: ...77 311 EEC YFM45FGHZ 78 3 dB A YFM45FGZ 78 3 dB A Vibration on seat EN1032 ISO5008 YFM45FGHZ Will not exceed 0 5 m s YFM45FGZ Will not exceed 0 5 m s Vibration on handlebar EN1032 ISO5008 YFM45FGHZ Will not exceed 2 5 m s YFM45FGZ Will not exceed 2 5 m s Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 421 cm Bore stroke 84 5 75 0 mm...

Page 156: ...S qt 0 44 Imp qt Differential gear oil Type YFM450FAZ Yamaha Friction Modified Shaft Drive Gear Oil Part No ACC SHAFT LU 00 or SAE 80 API GL 4 Hypoid gear oil YFM45FGHZ Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 API GL 4 Hypoid gear oil YFM45FGZ Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 API GL 4 Hypoid gear oil Quantity 0 23 L 0 24 US qt 0 20 Imp qt Cooling system Coolan...

Page 157: ...reduction system V belt 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 Reverse gear 29 17 1 706 Low range 45 16 2 813 High range 38 23 1 652 Chassis Frame type Steel tube frame Caster angle 2 5 Trail 8 5 mm 0 33 in Front tire Type Tubeless Size AT25 x 8 12 Manufacturer model YFM450FAZ CHENG SH...

Page 158: ...el Rim size 12 x 7 5AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Wet multiple disc brake Operation Left hand and right foot operation Front suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 160 mm 6 3 in Rear suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wh...

Page 159: ...D Park indicator light LED On Command four wheel drive differential gear lock indicator LCD 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 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Backup fuse 10 0 A Four wheel drive motor fuse 10 0 A U37S61E0 book Page 5 Tues...

Page 160: ... erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26041 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key id...

Page 161: ...del label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number front left side 1 Vehicle identification number 2 Year of manufacture 0 0 8 2008 9 2009 A 2010 B 2011 I O Q U Z not used 1 2 U37S61E0 book Page 2 Tuesday June 2 2009 10 3...

Page 162: ...11 3 11 1 Model label U37S61E0 book Page 3 Tuesday June 2 2009 10 33 AM ...

Page 163: ...6 Carrier front 4 21 Carrier rear 4 21 Chassis fasteners 5 7 Cleaning 9 1 Coolant 5 3 8 26 Coolant temperature warning light 4 2 D Differential gear oil 5 3 8 24 Drive select lever 4 13 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 38 Drive shaft universal joint lubricating 8 49 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 36 ...

Page 164: ...Part locations 3 1 R Rear knuckle pivots lubricating 8 50 Recoil starter 4 13 Reverse indicator light 4 2 Riding your ATV 7 1 S Safety information 2 1 Seat 4 18 Shock absorber assemblies adjusting the front and rear 4 21 Spark arrester cleaning 8 33 Spark plug checking 8 14 Specifications 10 1 Speed limiter 4 11 Stabilizer bushes checking 8 50 Starter choke 4 17 Start switch 4 6 Steering shaft lub...

Page 165: ...Wheel installing 8 59 Wheel removing 8 59 U37S61E0 book Page 3 Tuesday June 2 2009 10 33 AM ...

Page 166: ...YAMAHA MOTOR CO LTD PRINTED IN USA 2009 06 0 3 1 CR E U37S61E0 book Page 1 Tuesday June 2 2009 10 33 AM ...

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