Yamaha YFM45FGZ Owner'S Manual Download

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OPERATION .................................................. 6-1

Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Operating the drive select lever and

driving in reverse ...................................... 6-3

Engine break-in  .......................................... 6-5
Parking ....................................................... 6-5
Parking on a slope  ..................................... 6-6
Accessories and loading  ............................ 6-6

RIDING YOUR ATV ...................................... 7-1

GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND GOOD

JUDGMENT .............................................. 7-2

BE CAREFUL WHERE YOU RIDE............. 7-9
TURNING YOUR ATV .............................. 7-12
CLIMBING UPHILL ................................... 7-13
RIDING DOWNHILL.................................. 7-16
CROSSING A SLOPE............................... 7-17
CROSSING THROUGH SHALLOW

WATER ................................................... 7-18

RIDING OVER ROUGH TERRAIN ........... 7-21
SLIDING AND SKIDDING......................... 7-21
WHAT TO DO IF... .................................... 7-23
WHAT TO DO... ........................................ 7-23

PERIODIC MAINTENANCE AND
ADJUSTMENT................................................8-1

Owner’s manual and tool kit .......................8-1
Periodic maintenance chart for the

emission control system ...........................8-3

General maintenance and lubrication

chart ..........................................................8-5

system cable ...........................................8-38

Brakes .......................................................8-38
Checking the front brake pads and rear

brake friction plates .................................8-39

Checking the brake fluid level ...................8-40

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

Summary of Contents for YFM45FGZ

Page 1: ...AL DEL PROPIETARIO 37S F8199 61 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de s curit LEA ESTE MANUAL ATENT...

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: ...laan 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 2...

Page 5: ...anding 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 includ...

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 si...

Page 7: ...otorway 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 r...

Page 8: ...e 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...

Page 9: ...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 En...

Page 10: ...ub 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 Replacin...

Page 11: ...bels 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...

Page 12: ...s 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...

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: ...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 Tues...

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...

Page 16: ...th 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...

Page 17: ...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 lo...

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: ...n 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...

Page 22: ...hild 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...

Page 23: ...mbing 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 th...

Page 24: ...d 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 op...

Page 25: ...e 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 D...

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...

Page 27: ...andlebar 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 sw...

Page 28: ...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 electrica...

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...

Page 30: ...ism 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 in...

Page 31: ...ushing 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 format...

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 positio...

Page 33: ...he 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...

Page 34: ...ential 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 i...

Page 35: ...he 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 E...

Page 36: ...his 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...

Page 37: ...ntial 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...

Page 38: ...er 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...

Page 39: ...tle 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 brak...

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...

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 wh...

Page 42: ...loth 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 ca...

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...

Page 44: ...n 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 Startin...

Page 45: ...1 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 th...

Page 46: ...y 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 stora...

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...

Page 48: ...63 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 adju...

Page 49: ...ension 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 r...

Page 50: ...iary 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 a...

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...

Page 52: ...le 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 con...

Page 53: ...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...

Page 54: ...he 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 ma...

Page 55: ...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...

Page 56: ...ims 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 combin...

Page 57: ...ure 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 bo...

Page 58: ...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...

Page 59: ...gine 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 sh...

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...

Page 61: ...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 Yam...

Page 62: ...ine 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...

Page 63: ...lying 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 access...

Page 64: ...e 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...

Page 65: ...ith 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...

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...

Page 68: ...90 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...

Page 69: ...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...

Page 70: ...ch 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 describ...

Page 71: ...ide 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 goi...

Page 72: ...l 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 WARNI...

Page 73: ...he 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...

Page 74: ...aces 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 r...

Page 75: ...h 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...

Page 76: ...n 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 A...

Page 77: ...elease 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 EC...

Page 78: ...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...

Page 79: ...uddenly 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...

Page 80: ...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...

Page 81: ...ely 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...

Page 82: ...her 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 sha...

Page 83: ...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 you...

Page 84: ...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...

Page 85: ...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 U...

Page 86: ...n 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...

Page 87: ...ioning 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 direct...

Page 88: ...rying 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...

Page 89: ...inte 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...

Page 90: ...tenance 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...

Page 91: ...re 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 1...

Page 92: ...ss 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 2...

Page 93: ...ta 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...

Page 94: ...s 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 Sta...

Page 95: ...ect 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 coolan...

Page 96: ...ur 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 housin...

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...

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: ...ff 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 R...

Page 100: ...nder 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 Pa...

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...

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...

Page 103: ...lectrode 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 D...

Page 104: ...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 t...

Page 105: ...ne 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 ac...

Page 106: ...ll 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 u...

Page 107: ...age 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 filte...

Page 108: ...ecified 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 ca...

Page 109: ...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 F...

Page 110: ...hange 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 us...

Page 111: ...80W 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...

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...

Page 113: ...il 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 recommen...

Page 114: ...t 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 lev...

Page 115: ...ion 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...

Page 116: ...urface 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 th...

Page 117: ...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 recommende...

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 lubrica...

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...

Page 120: ...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 ma...

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 sea...

Page 122: ...park 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...

Page 123: ...ust 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...

Page 124: ...hout 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 adjus...

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 bef...

Page 126: ...r 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 pe...

Page 127: ...ning 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 bra...

Page 128: ...ow 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 pr...

Page 129: ...se 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 sea...

Page 130: ...g 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...

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...

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 directi...

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...

Page 134: ...t 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 lig...

Page 135: ...yed 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...

Page 136: ...cked 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 Rea...

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 inte...

Page 138: ...ar 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 sha...

Page 139: ...h 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 medic...

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 rem...

Page 141: ...gative 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 l...

Page 142: ...t 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 moto...

Page 143: ...evices 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 t...

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 u...

Page 145: ...690 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...

Page 146: ...b 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 hold...

Page 147: ...heel 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 w...

Page 148: ...apered 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...

Page 149: ...y 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 m...

Page 150: ...V 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 st...

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 c...

Page 152: ...n 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 bill...

Page 153: ...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 teaspoonfu...

Page 154: ...om 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 mor...

Page 155: ...7 311 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 Wil...

Page 156: ...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 D...

Page 157: ...eduction 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...

Page 158: ...l 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...

Page 159: ...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...

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 ke...

Page 161: ...el 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 V...

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

Page 163: ...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 le...

Page 164: ...art 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...

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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Yamaha YFM45FGZ, Owner'S Manual

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