Yamaha YFM45KDXK Owner'S Manual Download Page 162

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12-2

Label locations ...............................................................1-1
Light switch ....................................................................4-7

Main switch  ....................................................................4-1
Maintenance and lubrication chart  ................................8-5
Maintenance chart, emission control system  ................8-3
Maintenance record  .....................................................11-5
Model label ...................................................................11-2

Neutral indicator light .....................................................4-2
Noise regulation ...........................................................11-4

Owner’s Manual and tool kit ..........................................8-2

Panels, removing and installing  ...................................8-10
Park indicator light  .........................................................4-2
Parking ...........................................................................6-4
Parking on a slope  .........................................................6-5
Part locations  .................................................................3-1

Rear brake, adjusting the lever and pedal  ...................8-41
Rear knuckle pivots, lubricating  ...................................8-51
Reverse indicator light  ...................................................4-2
Riding your ATV  .............................................................7-1

Safety information ..........................................................2-1
Seat ..............................................................................4-13
Self-diagnosis device .....................................................4-5
Shock absorber assemblies, adjusting the front and

rear .............................................................................4-15

Throttle lever .......................................................... 4-8, 5 -4
Throttle lever free play, adjusting .................................8-38
Tires ............................................................................... 5-4
Trailer hitch (YFM45KPXK / YFM45KPLK /

YFM45KPHK) ............................................................. 4-16

Troubleshooting ........................................................... 8-65
Troubleshooting charts ................................................ 8-66

Valve clearance  ............................................................ 8-38
V-belt case drain plug  .................................................. 8-37
V-belt cooling duct check hose  ................................... 8-36
Vehicle Emission Control Information label  ................. 11-2
Vehicle identification number ....................................... 11-1

Warranty, extended ......................................................11-8
Warranty, limited  .......................................................... 11-6
Wheel hub bearings, checking ..................................... 8-49
Wheel, installing  ........................................................... 8-63
Wheel, removing  .......................................................... 8-63
Winch pre-wiring  .......................................................... 4-18

UBB511E0.book Page 2 Monday, March 5, 2018 3:26 PM

Summary of Contents for YFM45KDXK

Page 1: ...ould not be ridden by anyone under 16 years of age WARNING OWNER S MANUAL BB5 F8199 11 LIT 11626 32 08 YFM45KDXK YFM45KDHK YFM45KPXK YFM45KPLK YFM45KPHK READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ...r 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 ...

Page 3: ...mation It provides information about special techni ques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manual together with TIPS FOR THE ATV RIDER carefully and completely before operating your ATV Mak...

Page 4: ... the 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 vehi...

Page 5: ...effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17403 YFM45KDXK YFM45KDHK YFM45KPXK YFM45KPLK YFM45KPHK OWNER S MANUAL 2019 by Yamaha Motor Corporation U S A 1st edition February 2018 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Print...

Page 6: ...evice 4 5 Handlebar switches 4 6 Throttle lever 4 8 Speed limiter 4 8 Front brake lever 4 9 Brake pedal and rear brake lever 4 9 Drive select lever 4 10 Fuel tank cap 4 11 Fuel 4 12 Seat 4 13 Storage compartment 4 14 Front carrier 4 14 Rear carrier 4 15 Front and rear shock absorbers 4 15 Trailer hitch YFM45KPXK YFM45KPLK YFM45KPHK 4 16 Auxiliary DC jack 4 17 Winch pre wiring 4 18 PRE OPERATION CH...

Page 7: ...al and tool kit 8 2 Periodic maintenance chart Emission control system 8 3 Periodic maintenance chart General maintenance and lubrication 8 5 Removing and installing panels 8 10 Checking the spark plug 8 17 Engine oil and oil filter cartridge 8 19 Final gear oil 8 24 Changing the differential gear oil 8 27 Coolant 8 28 Cleaning the air filter 8 32 Cleaning the spark arrester 8 35 V belt cooling du...

Page 8: ...t 8 51 Battery 8 52 Replacing a fuse 8 55 Replacing a headlight bulb 8 58 Adjusting a headlight beam 8 61 Replacing the brake tail light bulb 8 62 Removing a wheel 8 63 Installing a wheel 8 63 Troubleshooting 8 65 Troubleshooting charts 8 66 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise regulation 11 4 Maintenance ...

Page 9: ...1 1 1 EBU17661 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 4 3 8 9 10 5 7 7 7 7 6 UBB511E0 book Page 1 Monday March 5 2018 3 26 PM ...

Page 10: ... before shifting 2UD F151E 00 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold Recommended FRONT 5 0 psi 35 kPa REAR 4 4 psi 30 kPa Minimum FRONT 4 6 psi 32 kPa REAR 4 0 psi 27 kPa Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING TRAI...

Page 11: ...he maximum rear cargo limit of 176 lbs 80 kg NEVER sit on the carrier Refer to instructions in the Owner s Manual 5880 N 1322 600 kgf 15 kgf 37S F151K 00 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open BB5 F2259 00 4 5 6 7 UBB511E0 book Page 3 Monday March 5 2018 3 26 PM ...

Page 12: ... ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate ALWAYS 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 use proper riding techniques to avoid vehicle overturns on hills and rough...

Page 13: ...ears 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 st...

Page 14: ...ls 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 b...

Page 15: ...g 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 16: ...and 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 nigh...

Page 17: ... 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 6 6 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 st...

Page 18: ...poorly 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 ...

Page 19: ...ter cartridge 8 Coolant reservoir 9 V belt cooling duct check hose 1 2 3 4 5 9 7 8 6 1 Spark arrester 2 Storage compartment and tool kit 3 Fuel tank cap 4 Spark plug 5 Auxiliary DC jack 6 Front shock absorber 7 Rear brake light switch 8 Brake pedal 9 V belt case drain plug 10 Rear shock absorber 1 10 6 2 3 4 5 7 9 8 UBB511E0 book Page 1 Monday March 5 2018 3 26 PM ...

Page 20: ...rake lever 2 Handlebar switches 3 Drive select lever 4 Display unit 5 Front brake fluid reservoir 6 On Command drive switch 2WD 4WD 7 Throttle lever 8 Front brake lever 9 Main switch 1 2 4 5 8 6 3 9 7 UBB511E0 book Page 2 Monday March 5 2018 3 26 PM ...

Page 21: ...started The key cannot be re moved off All electrical systems are off The key can be re moved EBU26697 Indicator lights and warning lights OFF ON 1 Neutral indicator light N 2 Reverse indicator light R 3 Park indicator light P 4 Coolant temperature warning light 5 Electric Power Steering warning light EPS for EPS model 6 Engine trouble warning light 7 Four wheel drive indicator light 1 2 3 4 6 7 5...

Page 22: ...ight 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 electrical circuit TIP The radiator fan turns on or off automatically ac cording to the coolant temperature NOTICE ECB02401 The engine may overheat if the ATV is over loaded Reduce the load to specification The engine may overheat if mud or dirt has accumulated on the radi...

Page 23: ...turning the key to on If the warning light does not come on have a Yamaha dealer check the electrical circuit TIP If the engine is stopped using the engine stop switch and the key is in the on position the EPS warning light comes on to indicate that the power assistance for the steering is not functioning If the steering load is too heavy i e excessive steering use when the ATV is traveling at a s...

Page 24: ... fuel gauge indicates the amount of fuel in the fuel tank The display segments of the fuel gauge disappear from F full towards E empty as the fuel level decreases When the last segment starts flashing refuel as soon as possible TIP This fuel gauge is equipped with a self diagnosis system If a problem is detected all the display segments will flash repeatedly If this occurs have a Yamaha dealer che...

Page 25: ...or one second TIP The odometer will lock at 99999 The tripmeter will reset and continue counting after 9999 9 is reached Service tripmeter The service tripmeter shows the distance traveled since it was reset at the last maintenance To reset the service tripmeter push the select but ton SEL for one second TIP The service tripmeter will reset and continue counting after 9999 9 is reached Hour meter ...

Page 26: ...his switch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running 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 EBU18102 Start switch Push this switch to crank the engine with the start er See the starting instructions on page 6 1 prior to starting the engine 1 Li...

Page 27: ...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 ter rain and riding conditions 2WD two wheel drive power is supplied to the rear wheels only giving a smooth ride and fuel economy 4WD four wheel drive power is supplied to the front and rear wheels giving maximum trac tion WARNING EWB00164 Always stop the ATV bef...

Page 28: ...keeps the throttle 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 1 Locknut 2 Adjusting screw 3 No m...

Page 29: ...ent 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 30: ... 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 6 2 for drive select lever operation 1 Rear brake lever 1 1 Drive select lever 1 UBB511E0 book Page 10 Monday March 5 2018 3 26 PM ...

Page 31: ...el 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 su...

Page 32: ...f 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 or AKI should be 86 or higher or RON 91 research octane number or higher If knocking or pinging occurs try a gasoline of a dif ferent brand or higher octane TIP ...

Page 33: ...system 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 UBB511E0 book Page 13 Monday March 5 2018 3 26 PM ...

Page 34: ...n the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage compartment Do not exceed the load limit of 2 0 kg 4 lb for the storage compartment Do not exceed the maximum load of 240 0 kg 530 lb for the ATV EBU18964 Front carrier Do not exceed the load limit of 40 0 kg 88 lb for the front carri...

Page 35: ...n cause poor handling and loss of stability which could lead to an ac cident Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension Align the appropriate notch in the adjusting ring with the position indicator on t...

Page 36: ...ceiver Trailer towing equipment can be obtained at a Yamaha dealer See page 6 6 for precaution in formation 1 Special wrench 1 Front spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 Rear spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 UBB511E0 book Page 16 Monday March 5 2018 3 26 PM ...

Page 37: ...s are turned off 1 Start the engine See page 6 1 2 Turn the headlights off See page 4 7 3 Turn the accessory off 4 Open the auxiliary DC jack cap 5 Insert the accessory power plug into the jack 1 Trailer hitch receiver 1 1 Auxiliary DC jack cap 2 Auxiliary DC jack Auxiliary DC jack maximum capacity 10 A 120 W 1 2 UBB511E0 book Page 17 Monday March 5 2018 3 26 PM ...

Page 38: ...ed without the engine running or with the headlights turned on the battery will lose its charge and engine start ing may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged EBU37290 Winch pre wiring This vehicle is equipped with pre wiring leads for a winch Consult your Yamaha dealer for details WARNING EWB00012...

Page 39: ...y a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 12 5 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 5 3 8 19 Final gear oil Check ATV for o...

Page 40: ...er free play and adjust if necessary 5 4 8 38 Control cables Make sure that operation is smooth Lubricate if necessary 8 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 5 4 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 49 Brake levers Mak...

Page 41: ... necessary See page 8 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 i...

Page 42: ... smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU38070 Tires Check and adjust the tire pressure before each ride Check tires for wear and damage Tire pressure A low pressure tire gauge is included as standard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first readin...

Page 43: ...V is equipped with tubeless tires and tire air valves After extensive tests only the tires list ed below are approved for this model by Yamaha 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 vehic...

Page 44: ... 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 Front Manufacturer model CHENG SHIN CU905 Size AT25 x 8 12 Rear Manufacturer model CHENG SHIN CU906 Size AT25 x 10 12 Maximum tire s...

Page 45: ... 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 6 4 prior to operating the engine for the first time To start the engine...

Page 46: ... 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 ECB00164 For maximum engine life never accelerate hard when the engine is cold EBU36230 Operating the drive select lever and driving in reverse NOTICE ECB03330 Do not shift without coming to a complete stop and waiting for the en...

Page 47: ...ople 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 select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park 1 2 L 3 H 4 N 5 R 6 P 1 Drive select lever 2 L Low range 3 H Hig...

Page 48: ...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 re sult in engine overheating 0 120 km 0 75 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not oper ate it at one set throt...

Page 49: ... applying the brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to the park position EBU20911 Accessories and loading EBU20922 Genuine Yamaha Accessories Choosing accessories for your ATV is an impor tant decision Genuine Yamaha Accessories which are available only from a Yamaha dealer have been designed tested and approved by Yamaha for use on your ATV Many comp...

Page 50: ... while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when...

Page 51: ...ad does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns ...

Page 52: ...6 8 6 WARNING EWB00012 Indicates a hazardous situation which if not avoided could result in death or serious injury UBB511E0 book Page 8 Monday March 5 2018 3 26 PM ...

Page 53: ...7 1 7 EBU21133 RIDING YOUR ATV UBB511E0 book Page 1 Monday March 5 2018 3 26 PM ...

Page 54: ...letely and understand the operation of the con trols Pay particular attention to the safety information on pages 2 1 2 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 increased if the ...

Page 55: ...characteristics 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 fo...

Page 56: ...ion 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 UBB511E0 book Page 4 Monday March 5 2018 3 26 PM ...

Page 57: ...oved 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 res...

Page 58: ...n page 5 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...

Page 59: ...s not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier vehicle takes longer to stop Avoid hills and rough terrain Choose terrain carefully Use extreme caution when towing or carrying a load on inclines Tur...

Page 60: ...e 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 an...

Page 61: ...the engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine ...

Page 62: ...y 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 UBB511E0 book...

Page 63: ... Stay 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 UBB511E0 book Page 11 Monday M...

Page 64: ...an 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 ot...

Page 65: ... wheels 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 no...

Page 66: ...to 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 sto...

Page 67: ... hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Always check the terrain carefully before you start up any hill Never climb hills with exces sively 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...

Page 68: ...m but not so fast that you cannot react to changes in the terrain as you climb It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steeper inclines standing 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 h...

Page 69: ...stopped apply the rear brake as well and then shift to the park position If you are in 4WD because all wheels are inter connected by the drive train applying either brake will brake all wheels therefore avoid sudden ap plication of either the front or rear brake as the wheels on the uphill side could come off the ground The ATV could easily tip over backwards Apply both the front and rear brakes g...

Page 70: ...ing your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Engine compression will do most of the braking for you For maximum engine com pression braking effect select the low range posi tion and change to 4WD before beginning to descend the hill Use caution while descending a hill with loose or slippery ...

Page 71: ...o turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Traversing a sloping surface on your ATV requires 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...

Page 72: ...ugh water Never operate this 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 ...

Page 73: ...e at the bottom of the air filter case and the V belt cooling duct check hose Also remove the V belt case drain plug 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 conditions 1 Air filter case check hose 1 V belt cooling duct check hose left front side o...

Page 74: ...tboards 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 sli...

Page 75: ...recommended 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 s...

Page 76: ...nd physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 15 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...

Page 77: ... Turn 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 2 6 for more information about carbon monoxide WARNING EWB0269...

Page 78: ...vided 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 Tool kit 2 Owner s Manual 3 Low pressure tire gauge 1 3 2 U...

Page 79: ... 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 Chec...

Page 80: ...alve and hose for damage Check condition and clean or replace if neces sary 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 UBB511E0 book Page 4 Monday March 5 2018 3 26 PM ...

Page 81: ...ecial 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 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 Sub air filter ele ment Clean and replace if necessary Every 20 40 hours more often in wet or...

Page 82: ... essary 8 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 9 Wheel hub bearings Check for looseness or damage and replace if necessary 10 V belt Check for wear cracks or other damage and re place if necessary 11 Drive shaft univer sal joint Lubricate with lithium soap based grease NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY ...

Page 83: ...se 17 Steering system Check operation and repair or replace if dam aged Check toe in and adjust if necessary 18 Engine mount Check for cracks or other damage and replace if necessary 19 Axle boots Check for cracks or other damage and replace if necessary 20 Engine oil Change Check ATV for oil leakage and correct if neces sary 21 Engine oil filter car tridge Replace 22 Engine oil strainer Clean NO ...

Page 84: ...bles Lubricate 27 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 28 Front and rear brake switches Check operation and correct if necessary 29 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150...

Page 85: ...t full throttle Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinder and calipers and chan ge the brake fluid Replace the brake hoses every four years and if cracked or damaged UBB511E0 book Page 9 Monday March 5 2018 3 26 PM ...

Page 86: ...Removing and installing panels The panels 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 1 Panel A 2 Panel B 2 1 1 Panel C 2 Panel D 3 Panel E 1 Panel F 1 3 2 1 UBB511E0 book Page 10 Monday March 5 2018 3 26 PM ...

Page 87: ...e sure that no foreign material enters the fuel tank ECB01052 To remove the panel 1 Remove the seat See page 4 13 2 Remove the bolts and quick fasteners 3 Remove the fuel tank cap and then pull the panel off 1 Bolt 1 1 Quick fastener 1 Fuel tank cap 1 1 1 UBB511E0 book Page 11 Monday March 5 2018 3 26 PM ...

Page 88: ...the bolts and quick fasteners 4 Install the seat Panels B and C When removing or installing panel C the drive se lect lever must be moved out of the park position Apply the brake pedal and move the drive select lever to the reverse position To remove a panel 1 Remove panel A 2 Pull the panel upward to release the tabs as shown UBB511E0 book Page 12 Monday March 5 2018 3 26 PM ...

Page 89: ...e the bolts and then take the panel off To install the panel Place the panel in the original position and then install the bolts Panel E To remove the panel Pull outward on the areas shown to release the projections and then slide the panel out 1 Bolt 2 Panel D 1 2 UBB511E0 book Page 13 Monday March 5 2018 3 26 PM ...

Page 90: ...nel F To remove the panel 1 Remove panels B and C 2 Remove the cover For YFM45KPXK YFM45KPLK YFM45KPHK Remove the handlebar mounted light cover See page 8 58 For YFM45KDXK YFM45KDHK Remove the handlebar cover YFM45KPXK YFM45KPLK YFM45KPHK 1 Handlebar mounted light cover 1 UBB511E0 book Page 14 Monday March 5 2018 3 26 PM ...

Page 91: ...M45KDHK 3 Remove the carrier top bolts 4 Remove the carrier bolts under the fenders and then take the carrier off 1 Handlebar cover 1 1 Carrier bolt top 2 Panel F 1 1 1 2 UBB511E0 book Page 15 Monday March 5 2018 3 26 PM ...

Page 92: ...the quick fasteners 6 Lift up the panel and disconnect the coupler 1 Carrier bolt under the fenders 1 Carrier bolt under the fenders 1 1 1 Quick fastener 1 Coupler 1 1 UBB511E0 book Page 16 Monday March 5 2018 3 26 PM ...

Page 93: ...K Install the handlebar cover 6 Install the panels EBU23215 Checking the spark plug The spark plug 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 ac cordance with the periodic maintenance and lubri cation chart In addition the condition of the spark plug can reveal the conditi...

Page 94: ... distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 2 Check the 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 1 Spark plug cap 1...

Page 95: ... be tightened to the speci fied torque as soon as possible 3 Install the spark plug cap EBU30245 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed 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 Remove pan...

Page 96: ...il level TIP The engine oil should be between the tip of the dipstick and the maximum level mark 6 If the engine oil is not between the tip of the dipstick and the maximum level mark add sufficient oil of the recommended type to raise it to the correct level NOTICE Be sure the engine oil is at the correct level other wise engine damage may result ECB00852 1 Engine oil filler cap 1 1 Engine oil fil...

Page 97: ...for several minu tes and then turn it off 4 Place an oil pan under the engine to collect the used oil 5 Remove the engine oil filler cap and then re move the engine oil drain bolt 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 panels C and D See page 8 10 7 Remove the oil filter cartridge with an oil filter wrench ...

Page 98: ...g of the new oil filter cartridge TIP Make sure that the O ring is properly seated 9 Install the new oil filter cartridge with an oil fil ter wrench and then tighten it to the specified torque with a torque wrench 1 Oil filter cartridge 1 Oil filter wrench 1 1 1 O ring UBB511E0 book Page 22 Monday March 5 2018 3 26 PM ...

Page 99: ... any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 1 Torque wrench Tightening torque Oil filter cartridge 17 N m 1 7 kgf m 13 lb ft Tightening torque Engine oil drain bolt 27 N m 2 7 kgf m 20 lb ft 1 Recommende...

Page 100: ...anged as follows at the intervals speci fied in the periodic maintenance and lubrication chart To check the final gear oil level 1 Park the ATV on a level surface 2 Remove the final gear oil filler bolt and its gas ket and then check the oil level in the final gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of th...

Page 101: ...o drain the oil from the final gear case 5 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 6 Refill with the recommended final gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material enters the final gear case ECB00422 1 Final gear case guard 2 Bolt 1 2 1 Final gear oil drain bolt 2 Gasket Tightening torque Final gear oil drai...

Page 102: ...heck the final gear case for oil leakage If oil is leaking check for the cause 10 Install the final gear case guard by installing the bolts and then tightening them to the specified torque 1 Final gear oil filler bolt 2 Gasket 3 Final gear oil 4 Correct oil level Recommended final gear oil Yamaha Friction Modified Shaft Drive Gear Oil Oil quantity 0 38 L 0 40 US qt 0 33 Imp qt 1 2 3 4 Tightening t...

Page 103: ...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 4 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the specified amount of the recom mended differential gear oil NOTICE Be sure no foreign material enters the differ ential gear c...

Page 104: ...The coolant level should be checked regularly In addition the coolant must be changed at the in tervals specified in the periodic maintenance and lubrication chart TIP If genuine Yamaha coolant is not available use an ethylene glycol antifreeze containing corrosion in hibitors for aluminum engines and mix with dis tilled water at a 1 1 ratio Recommended differential gear oil Yamaha Friction Modifi...

Page 105: ...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 3 If the coolant is at or below the minimum level mark remove panel C to access the coolant reservoir See page 8 10 1 Maximum level mark 2 Minimum ...

Page 106: ... 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 EBU37131 To change the coolant WARNING EWB01891 Wait for the engine and radiator to cool before removing the radiator cap You could be burned by hot fluid and steam ...

Page 107: ... or a similar object as shown to prevent coolant from spilling on the footrest 6 Remove the coolant reservoir cap 7 Disconnect the coolant reservoir hose on the coolant reservoir side and then drain the coolant from the coolant reservoir 1 Radiator cap 1 1 Coolant drain bolt 2 Gasket 3 Trough 2 1 3 UBB511E0 book Page 31 Monday March 5 2018 3 26 PM ...

Page 108: ...ol remove the radiator cap to check the coolant level in the radiator If it is low add sufficient coolant until it reach es the top of the radiator and then install the radiator cap 15 Install the panels and the front carrier EBU37113 Cleaning the air filter The main air filter element and sub air filter ele ment should be cleaned every 20 40 hours of en gine operation When servicing the air filte...

Page 109: ...ose empty the hose and clean the air filter case and air filter elements 1 Park the ATV on a level surface 2 Remove the seat See page 4 13 3 Remove the air filter case cover by unhooking the air filter case cover holders 4 Pull out the main air filter assembly and sub air filter element 1 Air filter case check hose 1 1 Air filter case cover holder 2 Air filter case cover 1 1 2 UBB511E0 book Page 3...

Page 110: ...hly with YAMALUBE Air Filter Cleaner or a dedicated parts cleaning solvent WARNING Always use parts cleaning sol vent Never use low flash point solvents or gasoline because the engine could catch fire or explode EWB01943 1 Main air filter assembly 1 Sub air filter element 1 1 1 Frame 2 Air filter element sponge material 3 Lock plate 1 2 3 UBB511E0 book Page 34 Monday March 5 2018 3 26 PM ...

Page 111: ...n air filter assembly 12 Install the air filter case cover by hooking the holders onto the cover NOTICE Make sure that the air filter element is properly seated in the air filter case Never operate the en gine with the air filter element removed Doing so would allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Additionally the fuel injection system would ...

Page 112: ...deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Check the gasket for damage Replace if nec essary 5 Install the gasket onto the tailpipe then insert the tailpipe into the muffler and align the bolt holes 6 Install the bolts and tighten to the specified torque EBU23921 V belt cooling duct check hose If dust or water collects in the V belt cooling duct c...

Page 113: ...t 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 1 V belt cooling duct check hose left front side of ATV 1 1 V belt case drain plug 1 UBB511E0 book Page 37 Monday March 5 2018 3 26 PM ...

Page 114: ...th 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 and lu brication chart EBU29602 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be performed by a Yamaha dealer WARNING EWB02572 Operating with im...

Page 115: ...s dam aged or if the lining thickness reaches the specified limit have a Yamaha dealer replace the brake pads as a set TIP The wheels need to be removed to check the brake pads See page 8 63 EBU30321 Rear brake friction plates The rear brake friction plates must be checked and if necessary replaced by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EBU2...

Page 116: ...wn have a Yamaha dealer the brake system 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 the filler cap before removing Use only DOT 4 brake fluid from a sealed contain er Use only the specified brake fluid otherwise the ru...

Page 117: ...oses 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 EBU30348 Adjusting the rear brake lever and brake pedal The rear brake lev...

Page 118: ...the brake lever free play turn the adjusting bolt in direction b NOTICE Distance A must not measure more than 12 7 mm 0 50 in If distance A exceeds 12 7 mm 0 50 in the specified brake lever free play cannot be obtained therefore proceed with the following steps ECB01143 1 Brake lever free play Brake lever free play 10 0 mm 0 39 in 1 1 Locknut 2 Distance A 3 Brake lever free play adjusting bolt 1 2...

Page 119: ...b NOTICE Make sure that distance B measures 22 mm 0 87 in or less If distance B reaches 22 mm 0 87 in adjust the brake lever free play at the brake lever again If distance A exceeds 12 7 mm 0 50 in have a Yamaha dealer check the vehicle ECB01153 7 Tighten the brake cable adjuster locknut 8 Slide the rubber cover to its original position 9 Tighten the locknut at the brake lever Adjusting the brake ...

Page 120: ...eight is within the specified limits 4 Tighten the locknut 5 Install the footboard by installing the quick fasteners bolts and nuts and then tighten the bolts to the specified torques Brake pedal height 80 0 mm 3 15 in 1 Footboard 2 Quick fastener 3 Bolt and nut 4 Bolt 4 2 3 3 1 2 1 Locknut 2 Adjusting bolt Tightening torque Locknut 7 N m 0 7 kgf m 5 2 lb ft 2 1 UBB511E0 book Page 44 Monday March ...

Page 121: ... order shown 1 Footboard bolt A 2 Footboard bolt B 3 Quick fastener 3 1 2 1 3 Tightening torques 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 1 4 3 2 5 5 UBB511E0 book Page 45 Monday March 5 2018 3 26 PM ...

Page 122: ...n direc tion a To decrease the brake pedal free play turn the adjusting nut in direction b 3 Tighten the locknut EBU24231 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them replaced by a Yamaha dealer 1 Brake pedal free play Brake pedal free play ...

Page 123: ...hould be adjusted by a Yamaha dealer Turn the rear brake light switch adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b 1 Front axle boot each side 1 Rear axle boot each side 1 1 1 1 1 Rear brake light switch 2 Rear brake light switch a...

Page 124: ...ontrols and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an accident or collision EBU28712 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be ch...

Page 125: ... each ride and the pedal pivot should be lubricated if necessary EBU24964 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play Recommended lubricant Lithium soap based grease UBB511E0 book Page 49 Monday March 5 2018 3 26 PM ...

Page 126: ...e periodic mainte nance chart TIP For parts equipped with a grease nipple use a grease gun EBU25023 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bush es if necessary Recommended lubricant Lithium soap based grease 1 Grease nipple 1 UB...

Page 127: ...equipped with a grease nipple use a grease gun EBU25095 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe riodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 UBB511E0 book Page 51 Monday March 5 2018 3 26 PM ...

Page 128: ...lyte or to add distilled water However the battery lead connections need to be checked and tightened and the bat tery terminals cleaned if corroded If the battery seems to have discharged recharge it as soon as possible TIP Wear gloves and eye protection in a ventilated area away from sparks and open flames Wash hands after handling It is recommended to have the battery serviced by a Yamaha dealer...

Page 129: ...gases Keep sparks flame cigarettes or other sources of ignition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN To remove the battery 1 Remove the seat See page 4 13 2 Remove the battery holding plate by remov ing the bolts 3 Disconnect the negative battery lead first then the positive battery lead by removing their bolt NOTICE When removing the bat tery th...

Page 130: ...ge 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 ...

Page 131: ...ive battery leads are installed as shown Fully charge the battery before installing it EBU30805 Replacing a fuse For non EPS models 1 Positive battery lead red 2 Negative battery lead black 2 1 1 Fuel injection system spare fuse 2 Fuel injection system fuse 3 Main fuse 4 Fuse box 1 2 3 4 UBB511E0 book Page 55 Monday March 5 2018 3 26 PM ...

Page 132: ... fuse 3 Ignition fuse 4 Radiator fan motor fuse 5 Signaling system fuse 6 Headlight fuse 7 Spare fuse 1 2 3 4 5 6 7 1 Fuel injection system spare fuse 2 Fuel injection system fuse 3 Main fuse 4 EPS fuse 5 Fuse box 1 2 3 4 5 UBB511E0 book Page 56 Monday March 5 2018 3 26 PM ...

Page 133: ...own fuse and then install a new fuse of the specified amperage WARNING Always use a fuse of the spec ified rating and never use a substitute ob ject in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical system which could lead to a fire EWB02173 1 Auxiliary DC jack fuse 2 Four wheel drive motor fuse 3 Ignition fuse 4 Radiator fan motor fuse 5 Signal...

Page 134: ...t 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 Specified fuses Main fuse 40 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Four wheel drive motor fuse 3 0 A Signaling system fuse 10 0 A Radiator fan motor fuse 20 0 A Auxiliary DC jack fuse 10 0 A Fuel injection system fuse 10 0 A EPS fuse 40 0 A YFM45KPHK YFM45KPLK YFM4...

Page 135: ...gers or other contamination will adversely affect the transparency 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 1 Bulb cover 1 Socket 1 1 1 Do not touch the glass part of the bulb UBB511E0 book Page 59 Monday March 5 2018 3 26...

Page 136: ... beam if necessary Handlebar mounted light bulb YFM45KPXK YFM45KPLK YFM45KPHK 1 Remove the handlebar mounted light cover by removing the quick fasteners 2 Remove the bulb cover by pulling it off 3 Remove the socket by pushing it in and turn ing it counterclockwise 1 Handlebar mounted light cover 2 Quick fastener 1 2 2 1 Bulb cover 1 Socket 1 1 UBB511E0 book Page 60 Monday March 5 2018 3 26 PM ...

Page 137: ...7 Install the bulb cover NOTICE Make sure the bulb cover is securely fitted over the socket and seated properly ECB03320 8 Install the handlebar mounted light cover as shown and then install the quick fasteners 9 Adjust the handlebar mounted light beam if necessary EBU25553 Adjusting a headlight beam NOTICE ECB00691 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight ...

Page 138: ...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 Headlight beam adjusting screw 1 Handlebar mounted light beam adjusting screw a b 1 1 a b 1 Brake tail light bulb holder 1 UBB511E0 book Page 62 Monday March 5 2018 3 26 PM ...

Page 139: ...he 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 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 1 Brake tail light bulb 1 1 Wheel nut 1 1 UBB511E0 book Page 63 Monday March 5 20...

Page 140: ...the wheel 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques 1 Arrow mark 2 Forward rotating direction 3 Wheel nut 1 2 3 1 Tapered nut Tightening torques Front wheel nut 55 N m 5 5 kgf m 41 lb ft Rear wheel nut 55 N m 5 5 kgf m 41 lb ft 1 UBB511E0 book Page 64 Monday March 5 2018 3 26 PM ...

Page 141: ...any repair take it to 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...

Page 142: ...ve 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 qu...

Page 143: ...mended 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 ...

Page 144: ...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 145: ...the 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 st...

Page 146: ...9 3 9 8 Remove the battery and fully charge it See page 8 52 UBB511E0 book Page 3 Monday March 5 2018 3 26 PM ...

Page 147: ...5 0 kg 650 lb YFM45KPHK YFM45KPLK YFM45KPXK Loading Maximum loading limit 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 421 cm Bore stroke 84 5 75 0 mm 3 33 2 95 in Compression ratio 10 0 1 Starting system Electric starter Lubrication system Wet sump ...

Page 148: ... 40 US qt 1 16 Imp qt Coolant reservoir up to the maximum level mark 0 25 L 0 26 US qt 0 22 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 Minimum research octane 91 Fuel tank capacity 14 L 3 7 US gal 3 1 Imp gal Fuel reserve amount 4 0 L 1 06 US gal 0 88 Imp gal Throttle body ID mark ...

Page 149: ...ufacturer model CHENG SHIN CU906 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 kPa 0 270 kgf cm 4 0 psi Front wheel Rim size 12 x 6 0AT Rear wheel Rim size 12 x 7 5AT Front brake Type Hydraulic disc brake Rear brake Type Mechanical w...

Page 150: ...bar mounted light T15H 35 0 W 36 5 W YFM45KPHK YFM45KPLK YFM45KPXK Brake tail light 21 0 W 5 0 W Meter lighting LED Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Parking brake indicator light LED Four wheel drive indicator light LED Engine trouble warning light LED EPS warning light LED YFM45KPHK YFM45KPLK YFM45KPXK Fuses Main fuse 40 0 A Headlight f...

Page 151: ...10 5 10 Four wheel drive motor fuse 3 0 A Radiator fan motor fuse 20 0 A EPS fuse 40 0 A YFM45KPHK YFM45KPLK YFM45KPXK UBB511E0 book Page 5 Monday March 5 2018 3 26 PM ...

Page 152: ...erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26021 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26031 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key ide...

Page 153: ...l be need ed when ordering spare parts from a Yamaha dealer EBU29663 Vehicle Emission Control Information label The Vehicle 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 identification number front left side 1 1 Model label 1 UBB511...

Page 154: ...11 3 11 1 Vehicle Emission Control Information label 1 UBB511E0 book Page 3 Monday March 5 2018 3 26 PM ...

Page 155: ...rpose 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 M...

Page 156: ... 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 UBB...

Page 157: ...nd make the machine available at that time for inspection and 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 ...

Page 158: ...d 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 ma...

Page 159: ...e 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 lodg...

Page 160: ...irst 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 YA...

Page 161: ... 8 28 Coolant temperature warning light 4 2 D Differential gear oil 5 3 Differential gear oil changing 8 27 Display unit 4 4 Drive select lever 4 10 Drive select lever and driving in reverse 6 2 Drive shaft universal joint lubricating 8 50 E Engine break in 6 4 Engine oil 5 3 Engine oil and oil filter cartridge 8 19 Engine stop switch 4 6 Engine trouble warning light 4 2 EPS warning light for EPS ...

Page 162: ...blies adjusting the front and rear 4 15 Spark arrester cleaning 8 35 Spark plug checking 8 17 Specifications 10 1 Speed limiter 4 8 Stabilizer bushes checking 8 50 Starting the engine 6 1 Start switch 4 6 Steering shaft lubricating 8 51 Storage 9 2 Storage compartment 4 14 T Throttle lever 4 8 5 4 Throttle lever free play adjusting 8 38 Tires 5 4 Trailer hitch YFM45KPXK YFM45KPLK YFM45KPHK 4 16 Tr...

Page 163: ...rm 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 ma...

Page 164: ...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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