Yamaha YFM45KDHM 2021 Owner'S Manual Download

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2. Remove the seat. (See page 5-23.)
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.

5. Pull off the air filter element lock plate, and

then remove the sponge material from the air
filter element frame.

1. Air filter case cover holder
2. Air filter case cover

1. Air filter element

UB5K12E0.book Page 37 Thursday, April 23, 2020 2:45 PM

Summary of Contents for YFM45KDHM 2021

Page 1: ...2 LIT 11626 34 29 This ATV should not be ridden by anyone under 16 years of age WARNING YFM70KDXM YFM70KDHM YFM70KPAM YFM70KPHM YFM70KPSM OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ... reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if i...

Page 3: ... ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manual together with TIPS FOR THE ATV RIDER carefully and completely before operating your ATV Make sure you understand all instructions For models equipped with a winch Read the...

Page 4: ...he figures shown in this manual This is the 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 vehicl...

Page 5: ...effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17403 YFM70KDXM YFM70KDHM YFM70KPAM YFM70KPHM YFM70KPSM OWNER S MANUAL 2021 by Yamaha Motor Corporation U S A 1st edition April 2020 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed ...

Page 6: ...ts 5 1 Multi function display YFM70KPAM YFM70KPHM YFM70KPSM 5 6 Handlebar switches 5 11 Drive lever 2WD 4WD YFM70KDXM YFM70KDHM 5 17 Throttle lever 5 18 Speed limiter 5 18 Front brake lever 5 19 Brake pedal and rear brake lever 5 19 Drive select lever 5 20 Fuel tank cap 5 21 Fuel 5 22 Seat 5 23 Storage compartment 5 24 Front carrier 5 25 Rear carrier 5 25 Front and rear shock absorbers YFM70KPAM Y...

Page 7: ...LOPE 8 20 CROSSING THROUGH SHALLOW WATER 8 21 RIDING OVER ROUGH TERRAIN 8 23 SLIDING AND SKIDDING 8 23 WHAT TO DO IF 8 24 PERIODIC MAINTENANCE AND ADJUSTMENT 9 1 Owner s Manuals and Tool Kit 9 2 Periodic maintenance chart Emission control system 9 3 Periodic maintenance chart General maintenance and lubrication 9 5 Removing and installing panels 9 9 Checking the spark plug 9 17 Engine oil and oil ...

Page 8: ... bushes 9 51 Lubricating the rear knuckle pivots 9 51 Lubricating the steering shaft 9 52 Battery 9 53 Replacing a fuse 9 56 Replacing a headlight bulb 9 59 Adjusting a headlight beam 9 62 Replacing the brake tail light bulb 9 63 Removing a wheel 9 64 Installing a wheel 9 64 Troubleshooting 9 65 Troubleshooting charts 9 66 CLEANING AND STORAGE 10 1 Cleaning 10 1 Storage 10 2 SPECIFICATIONS 11 1 CO...

Page 9: ... IDENTIFICATION NUMBER MODEL LABEL INFORMATION KEY IDENTIFICATION NUMBER EBU26032 Vehicle identification number The vehicle identification number is stamped into the frame This 17 digit number is used to identify your individual ATV EBU26053 Model label The model label is affixed at the location shown 1 Vehicle identification number front left side UB5K12E0 book Page 1 Thursday April 23 2020 2 45 ...

Page 10: ...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 1 Model label 1 Model type code 2 Production code 3 Color code 1 1 3 2 1 Key identification number UB5K12E0 book Page 2 Thursday April 23 2020 2 45 PM ...

Page 11: ...2 1 2 EBU17661 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 3 5 4 11 12 8 9 10 6 7 UB5K12E0 book Page 1 Thursday April 23 2020 2 45 PM ...

Page 12: ...cargo improperly can change handling stability and braking performance and can lead to an accident Never exceed the maximum front cargo limit of 110 lbs 50 kg NEVER sit on the carrier Refer to instructions in the Owner s Manual 187 lbs 85 kg B16 F4897 00 Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an accident Never exceed ...

Page 13: ...inimum It could cause the tire to dislodge from the rim LOADING TRAILER TOWING Cargo or a trailer can affect stability and handling Read owner s manual before loading or towing When riding with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Maximum Vehicle Load 530 lbs 240 kg Includes weight of operator cargo and accessories and if applicable trail...

Page 14: ... 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death 16 UNDER 1P0 F816L 01 Wait for the engine to return to normal idle speed before shifting 2UD F151E 00 9 8 UB5K12E0 book Page 4 Thursday April 23 2020 2 45 PM ...

Page 15: ...action plan submitted by YAMAHA and on file with the U S Consumer Product Safety Commission Certification of Compliance YAMAHA MOTOR CORPORATION U S A 6555 Katella Avenue Cypress California 90630 5101 U S A LOAD LIMIT 9lbs 4kg B4F F4877 U0 YAMAHA 4XE F1568 00 11 12 10 UB5K12E0 book Page 5 Thursday April 23 2020 2 45 PM ...

Page 16: ...rs old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and stre...

Page 17: ...s before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces 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 br...

Page 18: ... water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced 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 ...

Page 19: ...nd ride gently back to camp or other known location where you can receive medical at tention If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If your vehicle will not restart or is not in safe operating condition turn off the main switch and engine stop switch If the breakdown oc curs at twilight or night...

Page 20: ...You are responsible for injuries re lated to changes in the vehicle Keep the following guidelines in mind as well as those found in the Loading section page 7 7 when mounting acces sories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance limit suspension travel ste...

Page 21: ...oorly ventilated areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine 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 o...

Page 22: ...ake light switch 7 Engine oil dipstick 8 Oil filter cartridge 9 Coolant reservoir 5 1 2 3 4 7 8 6 9 1 Rear shock absorber 2 Fuel tank cap 3 Tool kit 4 Storage compartment 5 Spark plug 6 Winch equipped models 7 Front shock absorber 8 Brake pedal 9 V belt case drain plug 5 1 6 2 3 4 8 7 9 UB5K12E0 book Page 1 Thursday April 23 2020 2 45 PM ...

Page 23: ... reservoir 7 Front brake lever 8 Throttle lever 9 Auxiliary DC jack 10 Main switch 1 2 3 4 5 6 7 8 9 10 1 Drive select lever 2 Rear brake lever 3 Handlebar switches 4 Winch switch equipped models 5 Multi function display 6 Front brake fluid reservoir 7 On Command 4WD switches 8 Front brake lever 9 Throttle lever 10 Auxiliary DC jack 11 Main switch 1 2 3 5 6 7 8 9 1011 4 UB5K12E0 book Page 2 Thursd...

Page 24: ...tarted The key cannot be re moved off All electrical systems are off The key can be re moved EBU26699 Indicator lights and warning lights YFM70KDXM YFM70KDHM 1 Main switch 1 1 Fuel level warning light 2 Engine trouble warning light 3 Coolant temperature warning light 4 Neutral indicator light N 5 Reverse indicator light R 6 Park indicator light P 7 Four wheel drive indicator light 1 2 3 4 5 6 7 UB...

Page 25: ...es on when the transmis sion is in the reverse position EBU38270 Park indicator light YFM70KDXM YFM70KDHM YFM70KPAM YFM70KPHM YFM70KPSM This indicator light comes on when the transmis sion is in the park position 1 Differential gear lock indicator light 2 Low range indicator light L 3 High range indicator light H 4 Neutral indicator light N 5 Reverse indicator light R 6 Park indicator light 7 Four...

Page 26: ... the warning light remains on have a Yamaha dealer check the vehicle NOTICE ECB02040 The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the warning light is out Continuous use while this warn ing light is on may cause damage to the en gine YFM70KDXM YFM70KDHM If the light comes on during operation stop the ve hicle ...

Page 27: ...come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to on or if the warning light remains on have a Yamaha dealer check the vehicle YFM70KDXM YFM70KDHM This warning light comes on or flashes when an electrical circuit monitoring the engine is not work ing correctly When this occurs have a Yamaha dealer check the self diagnostic system YF...

Page 28: ...our wheel drive indicator light YFM70KDXM YFM70KDHM This indicator light comes on when the drivetrain is set to 4WD four wheel drive TIP Due to the synchronizing mechanism in the differ ential gear case the light may not come on until the ATV starts moving Four wheel drive icon YFM70KPAM YFM70KPHM YFM70KPSM This icon comes on when the drivetrain is set to 4WD four wheel drive TIP Due to the synchr...

Page 29: ...code display Speedometer The speedometer shows the vehicle s traveling speed The speedometer can be set to MPH or km h This also changes the odometer and trip meter units between miles and kilometers To change the display between MPH and km h turn the key to off then while holding the SELECT button pushed turn the key to on 1 Speedometer 2 Odometer Tripmeter A Tripmeter B Service tripmeter Error c...

Page 30: ... reset at the last maintenance Push the SELECT button to switch between the odometer ODO the tripmeters TRIP A and TRIP B and the service tripmeter in the following order ODO TRIP A TRIP B ODO To reset a tripmeter set the display to the tripme ter you want to reset then push the RESET but ton for 2 seconds TIP The odometer will lock at 199999 The tripmeters will reset and continue counting after 9...

Page 31: ...e coolant temperature display in the following order CLOCK HOUR VOLT CLOCK To set the clock 1 Set the display to the clock 2 Push both the SELECT button and RE SET button for 2 seconds The hour digits will start flashing 3 Use the RESET button to set the hours 4 Push the SELECT button and the minute digits will start flashing 5 Use the RESET button to set the minutes 6 Push the SELECT button and t...

Page 32: ...air the vehicle Coolant temperature display When the coolant is in the normal operating tem perature range the temperature is displayed When the coolant temperature rises the coolant temperature display will begin to flash If the cool ant temperature continues to rise the message Hi will flash TIP The coolant temperature display can be set to C or F To switch the temperature units turn the key to ...

Page 33: ...y 4 0 L 1 06 US gal 0 88 Imp gal of fuel remains Refuel as soon as possible TIP If the electrical circuit for the fuel gauge is not working correctly all display segments will flash repeatedly Have a Yamaha dealer check the vehi cle Brightness control mode This mode allows you to adjust the brightness of the multi function display when the vehicle is stopped To adjust the brightness 1 Push the SEL...

Page 34: ... light will come on or flash and the display will indicate an error code If the display indicates an error code note the code number and have a Yamaha dealer check the vehicle NOTICE ECB00812 If the multi function display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage EBU18068 Handlebar switches YFM70KDXM YFM70KDHM 1 Error code display 2 E...

Page 35: ...g Use this switch to stop the engine in an emergency situa tion The engine will not start or run when this switch is set to 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE 5 Winch switch OUT IN equipped models 4 3 2 1 5 1 On Command drive switch 2WD 4WD 2 On Command drive switch 4WD LOCK 3 Drive switch lock lever 2WD 4WD LOCK 4WD 3 3 2 1 UB5K12E0 book Page 12 Thur...

Page 36: ...l not have enough power to crank the engine If this should happen remove the bat tery and recharge it See page 9 53 EBU39181 Winch switch OUT IN equipped models This switch is used when operating the winch page 5 27 Read this manual and the Winch Owner s Manual completely before operating the winch switch EBU18192 Override switch OVERRIDE YFM70KPAM YFM70KPHM YFM70KPSM Top speed is normally limited...

Page 37: ...n 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 EBU2660A On Command drive switch 2WD 4WD YFM70KPAM YFM70KPHM YFM70KPSM Stop the ATV and push this switch to change from two wheel drive to four wheel drive or vice versa Select the appropriate drive according to the t...

Page 38: ...to the terrain and the conditions 4WD four wheel drive power is supplied to the front and rear wheels with the front differen tial unlocked LOCK four wheel drive with the differential gear locked power is supplied to the front and rear wheels and the differential gear is locked Unlike in four wheel drive all wheels turn at the same speed giving maximum traction WARNING EWB00132 Always stop the ATV...

Page 39: ...ged or disengaged When the ATV is in four wheel drive differential gear lock the maximum traveling speed is limit ed to 35 km h 22 mi h However if conditions require full engine power to be available push and hold the override switch to disable the dif ferential gear lock speed limiter See page 5 13 WARNING EWB00141 Always ride at a slow speed when the ATV is in differential gear lock and allow ex...

Page 40: ...rear wheels giving increased trac tion WARNING EWB00164 Always stop the ATV before changing from two wheel drive to four wheel drive and vice versa The ATV handles differently in two wheel drive than in four wheel drive in some circumstances Changing from two wheel drive to four wheel drive or vice versa while moving may cause the ATV to unexpectedly handle differently This could distract the oper...

Page 41: ...hrottle from fully opening even when the throttle lever is pushed to the maximum Adjusting the speed limiter 1 Loosen the locknut 2 To increase the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in direction a To decrease the maximum engine power avail able and the maximum speed of the ATV turn 1 Throttle lever 2WD 4WD 1 1 Locknut 2 Adjusting screw 3 No mo...

Page 42: ...nt of the speed limiter and throttle could cause throttle cable damage or improper throttle operation You could lose control resulting in an accident EWB00242 3 Tighten the locknut EBU18393 Front brake lever The front brake lever is located on the right han dlebar To apply the front brake pull the brake le ver toward the handlebar grip EBU18444 Brake pedal and rear brake lever 1 Front brake lever ...

Page 43: ...the brake pedal or pull the brake lever toward the handlebar grip EBU18614 Drive select lever The drive select lever is used to shift the transmis sion into the low range high range neutral re verse and park positions See page 7 2 for drive select lever operation 1 Rear brake lever 1 1 Drive select lever 1 UB5K12E0 book Page 20 Thursday April 23 2020 2 45 PM ...

Page 44: ...l while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun...

Page 45: ...ediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes About the recommended fuel This model s engine has been designed to use regular unleaded gasoline The pump octane number R M 2 should be 86 or higher or RON 91 octane or higher If knocking or pinging occurs try a gasoline of a different brand or higher octane TIP Gasoline conta...

Page 46: ...ystem EBU34141 Seat To remove the seat Pull up the seat at the rear and then pull the seat rearward To install the seat Insert the projections on the front of the seat into the seat holders and then push down on the seat at the rear to lock it in place Make sure that the seat is securely fitted 1 Seat 1 1 Projection 2 Seat holder 1 1 2 2 UB5K12E0 book Page 23 Thursday April 23 2020 2 45 PM ...

Page 47: ...the storage compartment open the storage compartment lid When storing any documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the vehi cle be careful not to let any water enter the stor age compartment Do not exceed the load limit of 4 0 kg 9 lb for the storage compartment Do not exceed the maximum load of 240 0 kg 530 lb for the v...

Page 48: ... ATV EBU1914A Front and rear shock absorbers YFM70KPAM YFM70KPHM YFM70KPSM The spring preload can be adjusted to suit the rid er s weight and the riding conditions WARNING EWB00401 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 Adjust the spring preload as fo...

Page 49: ...ng with the position indicator on the shock absorber 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 UB5K12E0 book Page 26 Thursday April 23 2020 2 45 PM ...

Page 50: ... winch unless all bystanders are Front spring preload setting Minimum soft 1 YFM70KPAM YFM70KPHM YFM70KPSM Standard 2 YFM70KPAM YFM70KPHM YFM70KPSM Maximum hard 5 YFM70KPAM YFM70KPHM YFM70KPSM Rear spring preload setting Minimum soft 1 YFM70KPAM YFM70KPHM YFM70KPSM Standard 2 YFM70KPAM YFM70KPHM YFM70KPSM Maximum hard 5 YFM70KPAM YFM70KPHM YFM70KPSM 1 Winch 2 Hook 3 Hook strap 4 Fairlead 1 3 2 4 U...

Page 51: ... s battery even when the engine is idling Allow the winch mo tor to cool and the battery to recharge between uses EBU28972 Trailer hitch equipped models This ATV is equipped with a 5 cm 2 in trailer hitch receiver Trailer towing equipment can be obtained at a Yamaha dealer See page 7 7 for precaution in formation 1 Trailer hitch receiver 1 UB5K12E0 book Page 28 Thursday April 23 2020 2 45 PM ...

Page 52: ...uch as a work light or radio with the proper adapter can be used when the main switch is turned on However to prevent bat tery drain use when the engine is running and the headlights are turned off 1 Start the engine 2 Turn the headlights off 3 Make sure the accessory is powered off 4 Open the auxiliary DC jack cap 5 Insert the accessory power plug into the jack 6 Turn the accessory on 1 Auxiliary...

Page 53: ...th the engine off or with the headlights on the battery may dis charge to the point that the engine will not start Do not use an automotive cigarette lighter or other accessory with a plug that gets hot The DC jack may be damaged WARNING EWB00012 Indicates a hazardous situation which if not avoided could result in death or serious injury UB5K12E0 book Page 30 Thursday April 23 2020 2 45 PM ...

Page 54: ... 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 5 22 6 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 6 3 9 19 Final gear oil Check ATV for oi...

Page 55: ... sure that operation is smooth Lubricate if necessary 9 48 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 6 4 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 9 50 Brake levers Make sure that operation is smooth Lubricate lever pivoting points i...

Page 56: ...necessary See page 9 28 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU28533 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 le ver and brake pedal If the free play is...

Page 57: ...raking performance check the brake pads and friction plates for wear See page 9 42 EBU19762 Throttle lever Check 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 EBU38073 Tires Check and adjust the tire pressure before each ride Check tires for wear and damage Tire pressure A low pressure tire gau...

Page 58: ...over Tire pressure below the minimum specified could also cause the tire to dislodge from the rim under severe driving conditions EWB04120 OPERATING TIRE PRESSURE cold FRONT Recommended 35 0 kPa 0 350 kgf cm 5 0 psi REAR Recommended 30 0 kPa 0 300 kgf cm 4 4 psi Front Minimum 32 0 kPa 0 320 kgf cm 4 6 psi Rear Minimum 27 0 kPa 0 270 kgf cm 4 0 psi Maximum load Vehicle 240 0 kg 530 lb The vehicle s...

Page 59: ...r extensive tests only the tires list ed below are approved for this model by Yamaha WARNING EWB02552 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent 1 Tire tread depth Front Manufacturer model MAXXIS MU19 Size AT25 x 8 12 Rear Manufacturer model MAXXIS MU20 Size AT25 x 10 12 Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa...

Page 60: ...f handling braking and comfort Other tires rims sizes and combinations may not be appropriate EBU19841 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened EBU19851 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary UB5K12E0 book Page 7 Thursday April 23 2020 2 45 PM ...

Page 61: ...an ignition circuit cut off system To enable starting one of the following conditions must be met The drive select lever is in the neutral or park po sition The rear brake lever or brake pedal is applied TIP It is recommended to shift into neutral or park and apply the rear brake when starting the engine NOTICE ECB00151 See the Engine break in section on page 7 4 prior to operating the engine for ...

Page 62: ...ear brake lever or brake pedal 4 Release the throttle lever then push the start switch to crank the engine with the starter Release the start switch when the engine has started TIP If the engine fails to start release the start switch Wait a few seconds before the next cranking at tempt to allow battery voltage to restore Do not crank the engine more than 10 seconds on any single attempt NOTICE EC...

Page 63: ...uld make you hit an obstacle or even a person behind you resulting in serious injury When you shift into reverse make sure there are no people or ob stacles behind you When it is safe to proceed go slowly 1 Bring the ATV to a complete stop 2 Apply the brake pedal 3 Shift from neutral to reverse or from reverse to park and vice versa by moving the drive se lect lever along the shift guide 1 Drive s...

Page 64: ...150 mi or 20 hours of operation For this reason you should fol low the engine break in instructions carefully Since the engine is brand new do not put an ex cessive load on it for the first 240 km 150 mi or 20 hours During this period the various parts in the engine wear and polish themselves to the cor rect operating clearances Avoid prolonged full throttle operation or any condition that might r...

Page 65: ... on a slope WARNING EWB00861 Avoid parking on hills or other inclines Parking on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident If you must park on an incline place the ATV transversely across the incline stop the engine shift the drive select lever to the park position and then block the front and rear wheels with rocks or other objects Do ...

Page 66: ...re not suitable because of po tential safety hazards to you or others Installing aftermarket products or having other modifica tions performed to your ATV that change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries re lated to changes in the vehicle Keep the following in mind when considerin...

Page 67: ... over loaded ATV can be unstable Do not exceed the maximum tongue weight You can measure tongue weight with a bath room scale Put the tongue of the loaded trailer on the scale with the tongue at hitch height Ad just the load in the trailer if necessary to reduce the weight on the hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum ATV load limit MAXIMUM LO...

Page 68: ...ly 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 trailer Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight...

Page 69: ...8 1 8 EBU21133 RIDING YOUR ATV UB5K12E0 book Page 1 Thursday April 23 2020 2 45 PM ...

Page 70: ...Manual com pletely and understand the operation of the con trols Pay particular attention to the safety information on pages 3 1 3 6 Also read all warn ing and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01382 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly incre...

Page 71: ...haracteristics Take the time to learn the basic techniques well before attempting more difficult maneuvers Become fa miliar with this ATV at slow speeds first even if you are an experienced operator Not recommended for children under 16 years of age WARNING EWB01391 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by children of ATVs that are not recommended for...

Page 72: ...on as needed during operation It is not for carry ing passengers WARNING Never carry a passenger Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV You could have an accident resulting in severe injury or death to you and or your passenger EWB01402 UB5K12E0 book Page 4 Thursday April 23 2020 2 45 PM ...

Page 73: ...ed motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01412 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 without eye protection can resul...

Page 74: ...page 6 1 Always follow the inspection and mainte nance procedures and schedules described in the Owner s Manual WARNING Failure to inspect the ATV before riding it or failure to maintain it properly increases the possibility of an acci dent and equipment damage EWB01433 Speed limiter For riders less experienced with this model the throttle lever housing is equipped with a speed limiter The speed l...

Page 75: ...ot 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 longer to stop Avoid hills and rough terrain Choose terrain carefully Use extreme caution when towing or carrying a load on inclines Turn g...

Page 76: ...your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident EWB01472 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 rid er accessories and ...

Page 77: ...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 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 p...

Page 78: ...seriously af fect 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 EWB01512 Do not ride on any public road street or highway Riding on public roads can result in collisions with other vehicles In many states it is illegal to oper ate ATVs on public streets roads and highways UB5K12E0 book P...

Page 79: ...tay alert for holes rocks or roots in the terrain and other hidden hazards which 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 EWB01532 UB5K12E0 book Page 11 Thursday A...

Page 80: ... accident includ ing an overturn EWB01542 When riding in an area where you might not easily be seen such as desert terrain mount a caution 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 off road ar eas where you cannot easily be seen Mount a caution flag on the ATV to make you more vis ible Watch carefully for othe...

Page 81: ...els may lift off the ground resulting in a loss of directional control Avoid higher speeds until you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident NOTICE ECB00252 Do not sh...

Page 82: ... the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly This procedure should be practiced at slow speed many times in a large off road area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop ...

Page 83: ...ATV to tip If the ATV be gins to tip over to the outside while negotiating a turn lean more to the inside It may also be nec essary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV UB5K12E0 book Page 15 Thursday April 23 2020 2 45 PM ...

Page 84: ...y slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 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 lev...

Page 85: ...ing on the footboards and leaning forward over the handlebars When ever possible ride straight up hills Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side there could be another person an obstacle or a sharp drop off Use common sense and remem ber that some hills are too steep for you to climb or descend If you are climbing a hill and you find that y...

Page 86: ...side Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in the Owner s Manual WARNING Stalling rolling backwards or improperly dismounting while climbing a hill could result in ATV overturning If you cannot control the ATV dismount immediately on the uphill side EWB01803 RIDING DOWNHILL WARNING EWB01622 Going down a hil...

Page 87: ...nd the hill Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hill...

Page 88: ...equires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose...

Page 89: ...ATV water deeper than the depth specified in your Owner s Man ual as tires may float increasing the risk of an overturn The ATV can be used to cross slow moving shal low water of up to a maximum of 35 cm 14 in in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly an...

Page 90: ...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 Also remove the drain plugs from the storage compartment and the V belt case to drain any water that may have accu mulated NOTICE Undrained water can cause damage or improper operation ECB00842 Wash the ATV in fresh water if it has been operat ed in salt water or muddy condit...

Page 91: ...oards at all times Avoid jumping the ATV as loss of control and damage to the ATV may result SLIDING AND SKIDDING WARNING EWB01663 Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slipp...

Page 92: ...commended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are reduced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost WHAT TO DO IF This sec...

Page 93: ... 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 8 16 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if t...

Page 94: ...urn off the engine when performing mainte 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 3 6 for more information about carbon monoxide WARNING EWB02691 ...

Page 95: ...ormation included in this manual and the tools provided in the tool kit are intended to assist you in the performance of preventive maintenance and minor repairs However additional tools such as a torque wrench are necessary to perform cer tain 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 M...

Page 96: ...ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 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 if necessary 4 Crankcase breath er system Check...

Page 97: ...eed valve and hose for damage Replace any damaged parts if necessary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 UB5K12E0 book Page 4 Thursday April 23 2020 2 45 PM ...

Page 98: ...lls NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 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 correct if necessary Repla...

Page 99: ... wear cracks or other damage and re place if necessary 10 Chassis 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...

Page 100: ...e and correct if neces sary 19 Engine oil filter car tridge Replace 20 Differential gear oil Change Check ATV for oil leakage and correct if neces sary 21 Final gear oil Change Check ATV for oil leakage and correct if neces sary 22 Cooling system Check coolant level and ATV for coolant leakage and correct if necessary Replace coolant Every 2 years NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whi...

Page 101: ...every four years and if cracked or damaged 23 Moving parts and cables Lubricate 24 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 25 Front and rear brake switches Check operation and correct if necessary 26 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB IN...

Page 102: ...shown need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU34180 Panel A To remove the panel Pull upward on the areas shown 1 Panel A 2 Panel B 3 Panel C 4 Panel D 5 Panel F 2 1 3 4 5 1 Panel E 2 Panel G 2 1 UB5K12E0 book Page 9 Thursday April 23 2020 2 45 PM ...

Page 103: ...the panel in the original position Panel B To remove the panel 1 Remove panel A 2 Remove the front carrier by removing the bolts 1 Panel A 1 1 Front carrier 2 Carrier bolt upper 1 2 2 UB5K12E0 book Page 10 Thursday April 23 2020 2 45 PM ...

Page 104: ...ard to remove it To install the panel 1 Place the panel in the original position and then install the quick fasteners 1 Carrier bolt under the fenders 2 Carrier bolt lower 1 2 2 1 1 Panel B 2 Quick fastener 1 2 2 UB5K12E0 book Page 11 Thursday April 23 2020 2 45 PM ...

Page 105: ... 1 Remove the seat See page 5 23 2 Remove panel A 3 Remove the hoses from panel C 4 Remove the quick fasteners and bolts Tightening torques Carrier bolt upper 34 N m 3 4 kgf m 25 lb ft Carrier bolt lower 34 N m 3 4 kgf m 25 lb ft Carrier bolt under the fenders 7 N m 0 7 kgf m 5 2 lb ft 1 Hose 1 1 UB5K12E0 book Page 12 Thursday April 23 2020 2 45 PM ...

Page 106: ...l the panel upward to remove it TIP To ease removal of panel C shift the drive select lever into the reverse position To install the panel 1 Place the panel in the original position 1 Bolt 2 Quick fastener 1 1 2 1 Screw 1 1 UB5K12E0 book Page 13 Thursday April 23 2020 2 45 PM ...

Page 107: ...perly connected and routed and are not pinched 3 Install panel A 4 Install the seat Panels D and E To remove a panel 1 Remove panels A and C 2 Remove the bolt and then pull the panel up ward to remove it 1 Panel D 2 Bolt 1 Panel E 2 Bolt 1 2 1 2 UB5K12E0 book Page 14 Thursday April 23 2020 2 45 PM ...

Page 108: ...ion and then install the bolt 2 Install panels A and C Panels F and G To remove a panel 1 Remove the panel bolts footboard bolt and footboard nut 1 Panel F 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection UB5K12E0 book Page 15 Thursday April 23 2020 2 45 PM ...

Page 109: ...on To install a panel 1 Place the panel in the original position 2 Install the bolts and nut and then tighten them to the specified torques 1 Panel G 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection UB5K12E0 book Page 16 Thursday April 23 2020 2 45 PM ...

Page 110: ...nce chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove panels A C and E See page 9 9 2 Remove the spark plug cap 3 Remove the spark plug as shown with the spark plug wrench included in the tool kit Tightening torques Panel bolt 4 0 N m 0 40 kgf m 3 0 lb ft Footboard nut 4 0 N m 0 40 kgf m 3 0 lb ft 1 Spark plug cap 1 Spark plu...

Page 111: ...he spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification To install the spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark ...

Page 112: ...d and the oil filter cartridge replaced at the intervals specified in the periodic maintenance chart To check the engine oil level 1 Park the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level warm up the engine and then wait at least 10 minutes until the oil settles for an accurate reading 3 Remove the access cover by t...

Page 113: ...he minimum level mark add sufficient oil of the recom mended type to raise it to the correct level NOTICE Be sure the engine oil is at the correct level otherwise engine damage may result ECB00852 7 Insert the dipstick completely into the oil filler hole 8 Install the access cover by turning it clock wise 1 Engine oil dipstick 1 Maximum level mark 2 Minimum level mark UB5K12E0 book Page 20 Thursda...

Page 114: ...and then remove the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 6 10 if the oil filter cartridge is not be ing replaced 6 Remove panel F See page 9 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 ...

Page 115: ...orque with a torque wrench 10 Install panel F 11 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the spec ified torque 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 N m 1 7 kgf m 13 lb ft Tightening torque Engine oil drain bolt 33 N m 3 3 kgf m 24 lb ft UB5K12E0 book Page 22 Thursday April 23 2020 2 45 PM ...

Page 116: ...ne off wait at least ten minutes and then check the oil level and correct it if necessary 15 Install the access cover by turning it clock wise EBU38620 Why Yamalube YAMALUBE oil is a Genuine YAMAHA Part born of the engineers passion and belief that engine oil is an important liquid engine component We form teams of specialists in the fields of mechanical en gineering chemistry electronics and trac...

Page 117: ... intervals speci fied in the periodic maintenance chart To check the final gear oil level 1 Park the ATV on a level surface 2 Remove the final gear oil level check bolt and its gasket and then check the oil level in the final gear case The oil level should be at the brim of the check hole 3 If the oil is below the brim of the check hole remove the final gear oil filler bolt and its gas ket and the...

Page 118: ...3 Remove the final gear oil filler bolt the final gear oil level check bolt the final gear oil drain bolt and their gasket to drain the oil from the final gear case 4 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 1 Final gear oil filler bolt 2 Gasket Tightening torques Final gear oil level check bolt 10 N m 1 0 kgf m 7 4 lb ft Final gear oil filler bol...

Page 119: ...ential gear oil The differential gear case must be checked for oil leakage before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In addition the differential gear oil level must be checked and the oil changed as follows at the in tervals specified in the periodic maintenance chart Tightening torque Final gear oil drain bolt 23 N m 2 3 kgf m 17 lb ft 1 Final gear oi...

Page 120: ...he oil filler bolt and its gasket and then tighten the bolt to the specified torque To change the differential gear oil 1 Park the ATV on a level surface 2 Place an oil pan under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt the differential gear oil drain bolt and their gasket to drain the oil from the differential gear case 1 Differential gear ...

Page 121: ...pecified torque 8 Check the differential gear case for oil leak age If oil is leaking check for the cause EBU23473 Coolant The coolant level should be checked regularly In addition the coolant must be changed at the in tervals specified in the periodic maintenance chart Tightening torque Differential gear oil drain bolt 9 8 N m 0 98 kgf m 7 2 lb ft 1 Differential gear oil filler bolt 2 Gasket 3 Di...

Page 122: ...o the en gine EBU34201 To check the coolant level 1 Park 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 Recommended coolant YAMALUBE coolant Coolant quantity Coolant reservoir up to full level 0...

Page 123: ...f coolant replace it with coolant as soon as possible otherwise the cooling system will not be protected against frost and corrosion 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 ECB01012 TIP The radiator fan is automatically switched on or off according to the ...

Page 124: ...r pressure Always place a thick rag over the cap when opening Allow any remaining pressure to escape before completely removing the cap 1 Park the ATV on a level surface 2 Remove panels A B C and D See page 9 9 3 Remove the footboard by removing the bolts and nuts 4 Remove the radiator cap 1 Footboard 2 Bolt and nut 3 Bolt 3 2 2 3 1 UB5K12E0 book Page 31 Thursday April 23 2020 2 45 PM ...

Page 125: ...remove the coolant drain bolt and its gasket Use a trough or a similar object as shown to prevent coolant from spilling on the engine guard 1 Radiator cap 1 1 Coolant drain bolt 2 Gasket 1 Trough 1 2 1 UB5K12E0 book Page 32 Thursday April 23 2020 2 45 PM ...

Page 126: ... gas ket and then tighten the bolt to the specified torque 11 Connect the coolant reservoir hose 12 Pour the recommended coolant into the radi ator until it is full 13 Pour the recommended coolant into the res ervoir to the maximum level mark and then install the reservoir cap 14 Loosen the water pump air bleed bolt with out removing it to allow all of the air to es cape from the air bleed bolt ho...

Page 127: ...to es cape from the air bleed bolt hole 19 When coolant begins to flow out of the bolt hole tighten the cylinder head air bleed bolt to the specified torque 20 Start the engine and let it idle for ten minutes 21 Rev the engine five times Tightening torque Water pump air bleed bolt 10 N m 1 0 kgf m 7 4 lb ft 1 V belt cooling duct 2 Clamp screw 1 2 1 Cylinder head air bleed bolt Tightening torque Cy...

Page 128: ...p 24 Start the engine and then check for coolant leakage TIP If any leakage is found have a Yamaha dealer check the cooling system 25 Install the V belt cooling duct and then tight en the clamp screw 26 Install the footboard by installing the bolts and nuts and then tighten them to the speci fied torques TIP Tighten footboard bolts B in the order shown 1 Footboard nut 2 Footboard bolt A 3 Footboar...

Page 129: ... dusty ar eas TIP There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air fil ter case 1 Park the ATV on a level surface Tightening torques Footboard nut 4 0 N m 0 40 kgf m 3 0 lb ft Footboard bolt A 4 0 N m 0 40 kgf m 3 0 lb ft Footboard bolt B 8 N m 0 8 kgf m 5 9 lb ft 4 1 2 3 1 Air filter case chec...

Page 130: ...olders 4 Pull the air filter element out of the air filter case 5 Pull off the air filter element lock plate and then remove the sponge material from the air filter element frame 1 Air filter case cover holder 2 Air filter case cover 1 2 1 1 Air filter element 1 UB5K12E0 book Page 37 Thursday April 23 2020 2 45 PM ...

Page 131: ...ply Yamaha foam air filter oil or other qual ity foam air filter oil to the sponge material TIP The sponge material should be wet but not drip ping 10 Pull the sponge material over the air filter ele ment frame and then install the lock plate 11 Insert the air filter element into the air filter case and then install the air filter case cover by hooking the holders onto the air filter case NOTICE M...

Page 132: ...and the rubber joint man ifold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine EBU28905 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester WARNING EWB02342 Always let the exhaust system cool prior to touching exhaust components Do not start the engine with the spar...

Page 133: ... bolt holes 6 Install the bolts and tighten to the specified torque EBU23932 V belt case drain plug After riding in water deep enough to allow it to en ter the V belt case remove the V belt case drain 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 Tightening torque ...

Page 134: ...ith use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance chart EBU29602 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be performed by a Yamaha dealer WARNING EWB02572 Operating with improperly service...

Page 135: ...allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indica tor groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared 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 9 64 EBU30322 Rear brake friction plates The rea...

Page 136: ...ge Therefore be sure to check the brake pads for wear and the brake system for leakage If the brake fluid level suddenly goes down have a Yamaha dealer check the brake sys tem before further riding WARNING EWB02721 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may allow air to enter the brake system reducing braking perfor mance Clean...

Page 137: ...brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EBU24396 Checking the front brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer in spect the brake system EBU34246 Adjustin...

Page 138: ...irection a To decrease the brake lever free play turn the adjusting bolt in direction b TIP If the specified brake lever free play could be ob tained as described above skip steps 3 8 3 Fully turn the adjusting bolt in direction a to loosen the brake cable 4 Slide the rubber cover back 1 Brake lever free play Brake lever free play 6 0 7 0 mm 0 24 0 28 in 1 1 Locknut 2 Brake lever free play adjusti...

Page 139: ...de the rubber cover to its original position 9 Tighten the locknut at the brake lever Adjusting the brake pedal free play Measure the brake pedal free play as shown If the free play is incorrect adjust it as follows 1 Remove panel G 2 Loosen the locknut 1 Brake cable adjuster locknut 2 Brake lever free play adjusting nut 3 Rubber cover 2 3 1 a b 1 Brake pedal free play Brake pedal free play 12 0 1...

Page 140: ...he locknut 5 Install the panel EBU24232 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance chart Check the axle boots for tears or damage If any damage is found have them replaced by a Yamaha dealer 1 Brake pedal free play adjusting nut 2 Locknut 2 a b 1 1 Front axle boot each side 1 1 UB5K12E0 book Page 47 Thursday April 23 2020 2 45 PM ...

Page 141: ...djusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EBU24905 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it 1 Rear ...

Page 142: ... 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 accident or collision EBU28712 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary Front brake lever Recommended lubrica...

Page 143: ...ke pedal pivot remove panel G See page 9 9 EBU24965 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bearings Recommended lubricant Lithium soap based grease UB5K12E0 book Page 50 Thursday Apr...

Page 144: ...periodic maintenance chart Have a Yamaha dealer replace the stabilizer bush es if necessary EBU25055 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance chart Recommended lubricant Lithium soap based grease UB5K12E0 book Page 51 Thursday April 23 2020 2 45 PM ...

Page 145: ...ing shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe riodic maintenance chart YFM70KDXM YFM70KDHM YFM70KPAM YFM70KPHM YFM70KPSM 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 UB5K12E0 book Page 52 Thursday April 23 2020 2 45 PM ...

Page 146: ...aler WARNING EWB02161 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flus...

Page 147: ...he main switch must be off and the negative lead must be disconnected be fore the positive lead ECB01002 5 Pull the battery out of its compartment 1 Front carrier 2 Carrier bolt upper 1 Carrier bolt under the fenders 2 Carrier bolt lower 1 2 2 1 2 2 1 1 Battery holding plate 2 Nut 3 Negative battery lead black 4 Positive battery lead red 1 2 4 3 UB5K12E0 book Page 54 Thursday April 23 2020 2 45 PM...

Page 148: ...e 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 ECB00942 Always keep the battery charged Storing the battery in a discharged state for an extended period of time will cause permanent battery damage Do not store the battery in an excessively cold or warm place below freezing or a...

Page 149: ...he battery before installing it EBU30525 Replacing a fuse 1 Positive battery lead red 2 Negative battery lead black Tightening torques Carrier bolt upper 34 N m 3 4 kgf m 25 lb ft Carrier bolt lower 34 N m 3 4 kgf m 25 lb ft Carrier bolt under the fenders 7 N m 0 7 kgf m 5 2 lb ft 1 2 1 Fuse box 2 Main fuse 3 EPS fuse YFM70KPAM YFM70KPHM YFM70KPSM 4 Fuel injection system spare fuse 5 Fuel injectio...

Page 150: ...rn off the main switch when checking or replacing a fuse 1 Headlight fuse 2 Signaling system fuse 3 Radiator fan motor fuse 4 Ignition fuse 5 Auxiliary DC jack fuse 6 Spare fuse 1 2 3 4 5 6 1 Headlight fuse 2 Radiator fan motor fuse 3 Signaling system fuse 4 Ignition fuse 5 Four wheel drive motor fuse 6 Auxiliary DC jack fuse 7 Spare fuse 1 2 3 4 5 6 7 UB5K12E0 book Page 57 Thursday April 23 2020 ...

Page 151: ...ge to the electrical system which could lead to a fire EWB02173 4 Turn on the main switch and start the engine Specified fuses Main fuse 40 0 A Headlight fuse 10 0 A YFM70KDHM YFM70KDXM 15 0 A YFM70KPAM YFM70KPHM YFM70KPSM Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A YFM70KPAM YFM70KPHM YFM70KPSM Signaling system fuse 10 0 A Auxiliary DC jack fuse 10 0 A Radiator fan motor fuse 20 0 A F...

Page 152: ...replace it with the specified bulb as follows Left and right headlight bulbs 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the bulb cover by pulling it off 3 Remove the socket by pushing it in and turn ing it counterclockwise 1 Cover at the rear of the headlight 1 1 Bulb cover 1 Socket 1 1 UB5K12E0 book Page 59 Thursday April 23 2020 2 45 PM ...

Page 153: ...t by pushing it in and turning it clockwise 7 Install the bulb cover and the cover at the rear of the headlight NOTICE Make sure the bulb cover is securely fitted over the sock et and seated properly ECB03320 8 Adjust the headlight beam if necessary Handlebar mounted light bulb YFM70KPAM YFM70KPHM YFM70KPSM 1 Remove the handlebar mounted light cover by removing the quick fasteners 2 Remove the bul...

Page 154: ...ncy of the glass luminosity of the bulb and bulb life Thoroughly clean off any dirt and fin gerprints using a cloth moistened with al cohol or thinner ECB00653 6 Install the socket by pushing it in and turning it clockwise 7 Install the bulb cover NOTICE Make sure the bulb cover is securely fitted over the socket and seated properly ECB03320 1 Bulb cover 1 Socket 1 1 1 Do not touch the glass part ...

Page 155: ...ng a headlight beam NOTICE ECB00691 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 1 Handlebar mounted light cover 1 1 Headlight beam adjusting screw b a 1 UB5K12E0 book Page 62 Thursday April 23 2020 2 45 PM ...

Page 156: ...ws 1 Remove the brake tail light bulb holder to gether with the bulb by turning it counter clockwise 2 Remove the burnt out bulb by pushing it in and turning it counterclockwise 1 Handlebar mounted light beam adjusting screw b a 1 1 Brake tail light bulb holder 1 Brake tail light bulb 1 1 UB5K12E0 book Page 63 Thursday April 23 2020 2 45 PM ...

Page 157: ...nd place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU36243 Installing a wheel 1 Install the wheel with the arrow mark pointing in the forward rotating direction of the wheel and then install the wheel nuts TIP For YFM70KDXM YFM70KDHM be sure to in stall the nuts with their tapered side towards the wheel 1 Wheel nut 1 1 1 Arrow mark 2 Forward rotating dir...

Page 158: ...o a Yamaha dealer whose skilled technicians have the necessary tools experience 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 EWB02281 Do not smoke when checking the fuel system Fuel can ignite or explode causing sev...

Page 159: ... 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 Check the compression Dry Wet Operate the electric starter Have a Yamaha dealer check the ATV The engine does not start Check the ignition Operate the electric starter 2 Battery The engine turns over quic...

Page 160: ...ended coolant as soon as possible The engine will tend to overheat if the radiator is caked with mud or if the ATV is overloaded 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 t...

Page 161: ...ion dry out the linings EWB02312 NOTICE Excessive wa ter pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure de tergent applications such as those avail able in coin operated car washers ECB00712 4 Once most of the dirt has been hosed off wash all surfaces with wa...

Page 162: ...he following steps to protect the en gine from internal 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 sparking during the next step d Turn the engine over several times with the sta...

Page 163: ...10 3 10 8 Remove the battery and fully charge it See page 9 53 UB5K12E0 book Page 3 Thursday April 23 2020 2 45 PM ...

Page 164: ...3 2 m 10 50 ft Maximum water depth 35 cm 14 in Weight Curb weight 299 0 kg 659 lb B6KC B6KF 311 0 kg 686 lb BGF4 BGF6 BGFC 324 0 kg 714 lb BGF9 Loading Maximum load 240 0 kg 530 lb Total weight of rider cargo accessories and tongue Engine Combustion cycle 4 stroke Cooling system Liquid cooled Valve train SOHC Number of cylinders Single cylinder Displacement 686 cm Bore stroke 102 0 84 0 mm 4 02 3 ...

Page 165: ...ACC SHAFT PL 32 or SAE 80 API GL 4 Hypoid gear oil Quantity 0 21 L 0 23 US qt 0 19 Imp qt Coolant quantity Radiator including all routes 1 99 L 2 10 US qt 1 75 Imp qt Coolant reservoir up to the maximum level mark 0 24 L 0 25 US qt 0 21 Imp qt Air filter Air filter element Wet element Air filter oil grade Foam air filter oil Fuel Recommended fuel Regular unleaded gasoline Gasohol E10 acceptable Mi...

Page 166: ...r 2 000 23 14 x 28 23 Low range 1 938 31 16 High range 1 148 31 27 Front tire Size AT25 x 8 12 Manufacturer model MAXXIS MU19 Rear tire Size AT25 x 10 12 Manufacturer model MAXXIS MU20 Tire air pressure measured on cold tires Vehicle load 0 0 240 0 kg 0 530 lb Recommended Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kP...

Page 167: ...o Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Lights Headlight T19L 30 0 W 30 0 W Handlebar mounted light T15H 35 0 W 36 5 W YFM70KPAM YFM70KPHM YFM70KPSM Brake tail light 21 0 W 5 0 W Meter lighting LED YFM70KPAM YFM70KPHM YFM70KPSM Neutral indicator light LED High beam indicator light LED YFM70KPAM YFM70KPHM YFM70KPSM Fuel level warning light LED YFM70KDHM YFM70KDXM Reverse indicator l...

Page 168: ...oltage warning light LED YFM70KPAM YFM70KPHM YFM70KPSM Fuses Main fuse 40 0 A Headlight fuse 10 0 A YFM70KDHM YFM70KDXM 15 0 A YFM70KPAM YFM70KPHM YFM70KPSM Signaling system fuse 10 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Fuel injection system fuse 15 0 A Four wheel drive motor fuse 10 0 A YFM70KPAM YFM70KPHM YFM70KPSM Radiator fan motor fuse 20 0 A EPS fuse 40 0 A YFM70KPAM YFM70KP...

Page 169: ... Emission Control Information label is affixed at the location in the illustration This label shows specifications related to exhaust emissions as required by federal law state law and Environ ment Canada 1 Vehicle Emission Control Information label 1 UB5K12E0 book Page 1 Thursday April 23 2020 2 45 PM ...

Page 170: ...ose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muf...

Page 171: ...the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 240 150 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 UB5K...

Page 172: ... repairs at such dealer s place of business 2 EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each applicable model Yamaha ATV covered by this warranty that the vehicle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and...

Page 173: ...upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CUSTOMER SERVICE If your mach...

Page 174: ... to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 250 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodgi...

Page 175: ...st 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your VIN number vehicle identification number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 Indicates a hazardous situation which if not avoided could result in death or serious injury WARNING YAMA...

Page 176: ...steners 6 7 Cleaning 10 1 Coolant 6 3 9 28 Coolant temperature warning light 5 3 D Differential gear lock indicators YFM70KPAM YFM70KPHM YFM70KPSM 5 5 Differential gear oil 6 3 9 26 Drive lever 2WD 4WD YFM70KDXM YFM70KDHM 5 17 Drive select lever 5 20 Drive select lever and driving in reverse 7 2 E Engine break in 7 4 Engine oil 6 3 Engine oil and oil filter cartridge 9 19 Engine stop switch 5 12 E...

Page 177: ...dicator light 5 2 Noise regulation 12 2 O On Command drive switch 4WD LOCK YFM70KPAM YFM70KPHM YFM70KPSM 5 15 Override switch YFM70KPAM YFM70KPHM YFM70KPSM 5 13 Owner s Manuals and Tool Kit 9 2 P Panels removing and installing 9 9 Park indicator light 5 2 Parking 7 5 Parking on a slope 7 5 Part locations 4 1 R Rear brake adjusting the lever pedal free play 9 44 Rear knuckle pivots lubricating 9 51...

Page 178: ...charts 9 66 V Valve clearance 9 41 V belt case drain plug 9 40 Vehicle Emission Control Information label 12 1 Vehicle identification number 1 1 W Warranty extended 12 6 Warranty limited 12 4 Wheel hub bearings checking 9 50 Wheel installing 9 64 Wheel removing 9 64 Winch equipped models 5 27 Winch switch equipped models 5 13 Y Yamalube 9 23 UB5K12E0 book Page 3 Thursday April 23 2020 2 45 PM ...

Page 179: ... right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manu...

Page 180: ...ntrol Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER C...

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Yamaha YFM45KDHM 2021, Owner'S Manual

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