Yamaha YFM4FGW Owner'S Manual Download Page 129

Page: 129 / 170

8-41

EBU27130

Adjusting the rear brake lever free play
and checking the brake pedal position

The brake lever free play must be adjusted and
brake pedal position must be checked and, if nec-
essary, adjusted at the intervals specified in the
periodic maintenance and lubrication chart.

NOTE:

●

Always perform this maintenance completely in
the following order whenever adjusting the rear
brake.

●

Before adjusting the brake lever free play and
checking the brake pedal position, check the
rear brake pads for wear.

Adjusting the brake lever free play

The brake lever free play should measure 0.5–2.0
mm (0.02–0.08 in) as shown. If the free play is in-
correct, adjust it as follows.

1. Loosen the locknut.
2. Turn the brake lever free play adjusting bolt in

direction (a) to increase the free play, and in
direction (b) to decrease it.

WHAT CAN HAPPEN
You could lose braking ability, which could
lead to an accident.
HOW TO AVOID THE HAZARD
After servicing:

●

Make sure the brakes operate smoothly
and that the free play is correct.

●

Make sure the brakes do not drag.

●

Make sure the brakes are not spongy. All
air must be bled from the brake system.

Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.

1. Brake lever free play

U1P113E0.book Page 41 Friday, May 19, 2006 9:10 AM

Summary of Contents for YFM4FGW

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety information This ATV should not be ridden by anyone under 16 years of age WARNING OWNER S MANUAL 1P1 F8199 13 LIT 11626 20 33 YFM4FGW ...

Page 2: ...EBU17091 U1P113E0 book Page 1 Friday May 19 2006 9 10 AM ...

Page 3: ...special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIO...

Page 4: ...o change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage to the ATV A NOTE provides key information to make procedures easier o...

Page 5: ... arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17401 AFFIX DEALER LABEL HERE YFM4FGW OWNER S MANUAL 2006 by Yamaha Motor Corporation U S A 1st edition May 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohi...

Page 6: ...ar switches 4 4 Throttle lever 4 6 Speed limiter 4 7 Front brake lever 4 8 Brake pedal and rear brake lever 4 9 Drive select lever 4 9 Recoil starter 4 10 Fuel tank cap 4 11 Fuel 4 11 Fuel cock 4 12 Starter choke 4 14 Seat 4 14 Storage compartment 4 15 Front carrier 4 16 Rear carrier 4 17 Adjusting the front and rear shock absorber assemblies 4 17 Auxiliary DC jack 4 18 PRE OPERATION CHECKS 5 1 Pr...

Page 7: ...7 RIDING OVER ROUGH TERRAIN 7 29 SLIDING AND SKIDDING 7 31 WHAT TO DO IF 7 32 WHAT TO DO 7 32 PERIODIC MAINTENANCE AND MINOR REPAIR 8 1 Owner s manual and tool kit 8 1 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing panels 8 9 Checking the spark plug 8 14 Engine oil and oil filter cartridge 8 16 Final gear oil 8 2...

Page 8: ...versal joint 8 46 Checking the stabilizer bushes 8 46 Lubricating the upper and lower arm pivots 8 46 Lubricating the knuckle pivots 8 46 Lubricating the knuckle shafts 8 47 Lubricating the steering shaft 8 47 Battery 8 47 Replacing a fuse 8 49 Replacing a headlight bulb 8 51 Adjusting a headlight beam 8 53 Replacing the tail brake light bulb 8 54 Removing a wheel 8 55 Installing a wheel 8 56 Trou...

Page 9: ...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 streets Nev...

Page 10: ...imbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully...

Page 11: ...n 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 tires speci...

Page 12: ...e pilot lights of water heaters and clothes dryers When transporting the ATV in another vehi cle be sure it is kept upright and that the fuel cock is in the OFF position Other wise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause inju ries HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some g...

Page 13: ...haust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad equate ventilation U1P113E0 book Page 5 Friday May 19 2006 9 10 AM ...

Page 14: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U1P113E0 book Page 1 Friday May 19 2006 9 10 AM ...

Page 15: ...TV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer U1P113E0 book Page 2 Friday May 19 2006 9 10 AM ...

Page 16: ...2 3 2 U1P113E0 book Page 3 Friday May 19 2006 9 10 AM ...

Page 17: ...2 4 2 U1P113E0 book Page 4 Friday May 19 2006 9 10 AM ...

Page 18: ... cap 10 Oil filter cartridge 11 Coolant reservoir 12 V belt cooling duct check hose 1 Rear shock absorber assembly spring preload adjusting ring 2 Spark arrester 3 Storage compartment and tool kit 4 Spark plug 5 Rear brake fluid reservoir 6 Front shock absorber assembly spring preload adjusting ring 7 Brake light switch 8 Brake pedal 9 V belt case drain plug U1P113E0 book Page 1 Friday May 19 2006...

Page 19: ... the figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Starter choke 4 Drive select lever 5 Speedometer 6 Main switch 7 Fuel tank cap 8 Auxiliary DC jack 9 On Command four wheel drive switch 10 Throttle lever 11 Front brake lever U1P113E0 book Page 2 Friday May 19 2006 9 10 AM ...

Page 20: ...tch The positions of the main switch are as follows ON All electrical systems are supplied with power The headlights meter lighting and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U1P113E0 book Page 1 Friday May 19 2006 9 10 AM ...

Page 21: ...g to the following procedure 1 Set the engine stop switch to and turn the key to ON 2 Shift the drive select lever into the neutral po sition or park position 3 Push the start switch If the warning light does not come on while the start switch is pushed have a Yamaha dealer check the electrical cir cuit CAUTION ECB00010 The engine may overheat if the ATV is over loaded In this case reduce the load...

Page 22: ... park position EBU18010 Speedometer The speedometer shows the riding speed This speedometer is equipped with a tripmeter The tripmeter can be reset to 0 with the reset knob Use the tripmeter to estimate how far you can ride on a tank of fuel before going to reserve This infor mation will enable you to plan fuel stops in the fu ture EBU18050 Fuel gauge The fuel gauge indicates the amount of fuel in...

Page 23: ...080 Engine stop switch Set this 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 situation The engine will not start or run when this switch is set to 1 Fuel gauge 2 Red line 1 Light switch OFF 2 Engine stop switch 3 Start switch U1P113E0 book Page 4 Friday May 19 2006 9 10 A...

Page 24: ...scharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU18200 On Command four wheel drive switch 2WD 4WD This ATV is equipped with a switch to change from two wheel drive to four wheel drive and vice versa Select the appropriate drive according to the ter rain and the conditions 2WD two wheel drive Power is supplied to the r...

Page 25: ...wheel drive to four wheel drive or from four wheel drive to two wheel drive while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in two wheel drive than in four wheel drive in some cir cumstances Changing from two wheel drive to four wheel drive or from four wheel drive to two wheel drive while moving may cause the ATV to unexpectedly handle differently This could distract the opera...

Page 26: ...V turn the adjusting screw in direction a To de crease the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in direction b 1 Throttle lever POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate mak ing it difficult to speed up or slow down when you need to This could cause an acci dent HOW TO AVOID THE HAZARD Check th...

Page 27: ...TIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Im proper throttle operation could result You could lose control have an accident or be in jured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjusted to 3 0 5 0 mm 0 12 0 20 in See page 8 36 1 ...

Page 28: ... the brake pedal or pull the brake lever toward the handlebar grip EBU18621 Drive select lever The drive select lever is used to shift your ATV into the forward neutral reverse and park positions See the Operating the drive select lever and driv ing in reverse section on page 6 3 for the drive se lect lever operation 1 Brake pedal 1 Rear brake lever U1P113E0 book Page 9 Friday May 19 2006 9 10 AM ...

Page 29: ...NG EWB00290 1 Drive select lever 1 Recoil starter POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position WHAT CAN HAPPEN The ATV could start to move unexpectedly which could cause an accident HOW TO AVOID THE HAZARD Set the drive select lever to the park position before starting the engine U1P113E0 book Page 10 Friday May 19 2006 9 10 AM ...

Page 30: ...ficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap 1 Fuel level 2 Fuel tank filler tube Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 15 0 L 3 96 US gal 3 30 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal U1P113E0 book Page 11 Friday May 19 2006 9 10 AM ...

Page 31: ...asohol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ATV performance problems WARNING EWB00270 EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPE...

Page 32: ...to this position when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark pointing to OFF 1 Arrow mark pointing to ON U1P113E0 book Page 13 Friday May 19 2006 9 10 AM ...

Page 33: ...choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke Move the starter choke in direction b to turn off the starter choke See the Starting a cold engine section on page 6 1 for proper operation EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at ...

Page 34: ...1 Storage compartment The storage compartment is located under the seat See page 4 14 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 ATV be careful not to let any water enter the storage compartment 1 Seat 2 Seat lock lever 1 Projection 2 Seat holder U1P113E0 book Page 15 Friday May 19 2006 9 10 AM ...

Page 35: ...ompartment Do not exceed the maximum load of 210 0 kg 463 lb for the ATV NOTE There is a check hose at the bottom of the storage compartment If any water collects in this hose re move the hose empty it and then install it EBU18960 Front carrier Do not exceed the load limit of 40 0 kg 88 lb for the front carrier Do not exceed the maximum load of 210 0 kg 463 lb for the ATV 1 Storage compartment 1 S...

Page 36: ...o suit the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Positi...

Page 37: ...ge 6 1 3 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 POTENTIAL HAZARD Improper shock absorber assembly adjust ment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock a...

Page 38: ...ith 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 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death 1 Auxiliary DC jack cap 1 Auxiliary DC jack Maximum rated capacity for the auxiliar...

Page 39: ...mended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 4 8 16 Final gear oil Check ATV for oil leakage Correct if necessary 5 4 8 21 Differential gear oil Check ATV for oil leakage Correct if necessary 5 4 8 23 Coolant Check coolant level in reservoir and add recommended coolant to specified level if necessary Check cooling system for leakage Correct if necess...

Page 40: ...Lubricate if necessary 8 44 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 6 5 7 5 8 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 45 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 45 Axle b...

Page 41: ...t damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual U1P113E0 book Page 3 Friday May 19 2006 9 10 AM ...

Page 42: ...OTE The coolant level must be checked on a cold en gine since the level varies with engine tempera ture WARNING EWB00490 POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill...

Page 43: ...r check the brake system Brake fluid level Check the brake fluid level Add fluid if necessary See page 8 38 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If a lever moves slow ly inward there may be a leak in the brake system If there is any leakage the brake system should be checked by a Yamah...

Page 44: ...ways check the brakes at the start of every ride Do not ride the ATV if you find any prob lem with the brakes If a problem cannot be corrected by the adjustment procedures pro vided in this manual have a Yamaha dealer check for the cause POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or opera tion o...

Page 45: ...ures must be equal on both sides Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm Rear 250 kPa 36 psi 2 5...

Page 46: ...t the tire pressures to the following specifications EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm 0 12 in 1 Low pressure tire gauge Recommended pressure Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1...

Page 47: ...t all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary 1 Tire wear limit U1P113E0 book Page 9 Friday May 19 2006 9 10 AM ...

Page 48: ...AZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an acci dent or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer POTENTIAL HAZARD Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to...

Page 49: ...to the fig ure Position 1 Cold engine start with ambient temperature below 5 C 40 F Position 2 Cold engine start with ambient temperature between 0 C 30 F and 30 C 90 F Position 3 Cold engine start with ambient temperature above 25 C 80 F Ambient temp starter choke position 5 Apply the rear brake lever 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE If t...

Page 50: ...efore riding NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter choke is not required when the engine is warm Instead start the engine with the throttle slightly open EBU20450 Operating the drive select lever and driving in rev...

Page 51: ...the brake pedal 3 Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide NOTE When in reverse the reverse indicator light should come on If the indicator light does not come on have a Yamaha dealer check the elec trical circuit 1 Drive select lever 2 F Forward 3 N Neutral 4 R Reverse 5 P Park 1 Drive select lever 2 F Forward 3 N ...

Page 52: ...longed full throttle operation or any condi tion that might result in engine overheating must be avoided 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine freely but do not use full throttle at any time 20 hours and beyond The ATV can now ...

Page 53: ...which has accessories Choose only accessories designed for your ATV Your Yamaha dealer has a variety of gen uine Yamaha accessories Other accessories may also be available on the market However POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If...

Page 54: ...e differently than it does without accessories EBU21050 Loading Cargo or a trailer can change the stability and han dling of an ATV You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable Do not exceed the maximum tongue weight You can measure tongue weight with a b...

Page 55: ...he slower you should go 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 affects the stability and handling of the ATV WARNING EWB00750 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death POTENTIAL HAZARD Overloading this ATV o...

Page 56: ...7 1 7 EBU21131 RIDING YOUR ATV U1P113E0 book Page 1 Friday May 19 2006 9 10 AM ...

Page 57: ... over a period of time Take the time to learn the ba sic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable ac tivity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manua...

Page 58: ... children under 16 years of age WARNING EWB00901 POTENTIAL HAZARD Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training cours...

Page 59: ...Vs that are not recom mended for their age can lead to severe inju ry or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc U1P113E0 book Page 4 Friday May 19 2006 9 10 AM ...

Page 60: ...AN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as need ed during operation It is not for carrying passengers U1P113E0 book Page 5 Friday May 19 2006 9 10 AM ...

Page 61: ...ye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or ...

Page 62: ...Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always ...

Page 63: ...loss of control in creasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this ATV on page 5 6 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 7 POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control ...

Page 64: ...d See page 4 7 Loading and accessories Use extra caution when riding the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Re duce your speed when adding additional loads 1 Adjusting screw MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 210 0 kg 463 lb Front carrier 40 0 kg 88 lb Rear carrier 80 0 kg 176 ...

Page 65: ...accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer U1P113E0 book Page 10 Friday May 19 2006 9 10 AM ...

Page 66: ...or could cause you to lose your balance and fall off of the ATV If you remove a foot from a foot board your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT C...

Page 67: ...ome situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nents designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer U1P113E0 book Page 12 ...

Page 68: ... accumulated around the engine area could catch fire Someone touching the exhaust system dur ing or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in a place where others might be likel...

Page 69: ...ewalks driveways parking lots and streets POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways U1P113E0 book Page 14 Friday May 19 2006 ...

Page 70: ...den rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Co...

Page 71: ...until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be in jured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch...

Page 72: ... the closed position and shift the drive select lever into the forward position Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is ap plied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds until you are thoroughly famil iar with the operation of your ATV Wh...

Page 73: ...ght If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of...

Page 74: ...ficult climbs only after you have devel oped your skill In all cases avoid inclines with slip pery or loose surfaces or obstacles that might cause you to lose control WARNING EWB01090 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 ...

Page 75: ...ou start up any hill Never climb hills with excessively 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 U1P113E0 book Page 20 Friday May 19 2006 9 10 AM ...

Page 76: ...ide Physically turn the ATV around and then descend the hill POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turn ing on...

Page 77: ...ckwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Shift to the park position after you are stopped If you begin rolling backwards Keep weight uphill 2WD Never apply the rear brake while roll ing backwards Apply...

Page 78: ... the downhill side Avoid sud den application of either the front or rear brake be cause the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles wh...

Page 79: ...7 24 7 U1P113E0 book Page 24 Friday May 19 2006 9 10 AM ...

Page 80: ...adually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING EWB01141 POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until yo...

Page 81: ...7 26 7 U1P113E0 book Page 26 Friday May 19 2006 9 10 AM ...

Page 82: ...ide your ATV without verifying that you have regained proper braking ability POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember th...

Page 83: ...hose the drive select lever box check hose and the storage compartment check hose Also remove the V belt case drain plug to drain any water that may have accumu lated Wash the ATV in fresh water if it has been operated in salt water or muddy conditions 1 Air filter case check hose 1 V belt cooling duct check hose left front side of ATV U1P113E0 book Page 28 Friday May 19 2006 9 10 AM ...

Page 84: ... or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult WARNING EWB01160 1 Drive select lever box check hose 1 Storage compartment check hose 1 V belt case drain plug POTENTIAL HAZARD Improperly operating over obstacles U1P113E0 book Page 29 Friday May 19 2006 9 10 AM ...

Page 85: ... HOW TO AVOID THE HAZARD Before operating in a new area check for ob stacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual U1P113E0 book Page 30 Friday May 19 2006 9 10 AM ...

Page 86: ...egained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are re duced Bear in mind that sliding maneuver...

Page 87: ...d if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 19 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side...

Page 88: ...wa ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See page 7 27 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death U1P113E0 book Page 33 Friday May 19 2006 9 10 AM ...

Page 89: ...D INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01820 EBU21720 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and always carry it on the bottom of the seat as shown Put the owner s tool kit and low pres sure tire gauge under the seat POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clo...

Page 90: ...wner s tool kit 3 Low pressure tire gauge POTENTIAL HAZARD Operating this ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added...

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

Page 92: ...ness and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U1P113E0 book Page 4 Friday May 19 2006 9 10 AM ...

Page 93: ...brake pads Whenever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake lever free play and adjust if neces sary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 4 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years 5 Wheels Check runout and for damage and repla...

Page 94: ...Knuckle pivots Lubricate with lithium soap based grease 15 Knuckle shafts Lubricate with lithium soap based grease 16 Steering shaft Lubricate with lithium soap based grease 17 Steering system Check operation and repair or replace if damaged 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 ...

Page 95: ...fety system cable Check operation and adjust or replace if neces sary 28 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 29 Front and rear brake switches Check operation and correct if necessary 30 Lights and switches Check operation and correct if necessary Adjust headligh...

Page 96: ...draulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U1P113E0 book Page 8 Friday May 19 2006 9 10 AM ...

Page 97: ... some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU27600 Panels A and D To remove one of the panels 1 Remove the seat See page 4 14 2 Pull outward on the areas shown and then pull upward as shown 1 Panel A 2 Panel B 1 Panel C 2 Panel D 3 Panel E 4 Panel F U1P113E0 book Page 9 Friday May 19 2006 9 10 AM ...

Page 98: ...8 10 8 To install one of the panels 1 Place the panel in its original position U1P113E0 book Page 10 Friday May 19 2006 9 10 AM ...

Page 99: ... bolt and then take the panel off To install the panel Place the panel in the original position and install the bolt CAUTION ECB00380 When installing the panel be sure not to pinch the cables or wires 1 Bolt 2 Panel B U1P113E0 book Page 11 Friday May 19 2006 9 10 AM ...

Page 100: ... bolts 2 Remove the carrier bolts under the fenders and then take the carrier off 3 Remove the quick fastener screws and then pull the panel upward to remove it 1 Carrier bolt top 1 Carrier bolt under the fenders U1P113E0 book Page 12 Friday May 19 2006 9 10 AM ...

Page 101: ...ll bolts to the specified torques Panel E To remove the panel Remove the bolts and then take the panel off To install the panel Place the panel in the original position and install the bolts Panel F To remove the panel Pull outward on the areas shown 1 Quick fastener screw 2 Panel C Tightening torques Carrier bolt top 34 Nm 3 4 m kgf 24 ft lbf Carrier bolt under fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1...

Page 102: ... will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove panel A See page 8 9 2 Remove the spark plug cap 1 Panel F 1 Spark plug cap U1P113E0 book Page 14 Friday May 19 2006 9 10 AM ...

Page 103: ...ent 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 To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spark pl...

Page 104: ...the panel EBU23322 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 spec ified in the periodic maintenance and lubrication chart To check the engine oil level 1 Remove panel F See page 8 9 2 Place the ATV on a level surface 3 Start the engine warm it up for several ...

Page 105: ... level marks 7 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level 8 Insert the dipstick into the oil filler hole and then tighten the engine oil filler cap 9 Install the panel 1 Engine oil filler cap 1 Dipstick 2 Maximum level mark 3 Minimum level mark U1P113E0 book Page 17 Friday May 19 2006 9 10 AM ...

Page 106: ...an oil pan under the engine to collect the used oil 5 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase NOTE Skip steps 6 10 if the oil filter cartridge is not being replaced 6 Remove panels D and E See page 8 9 7 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil drain bolt 1 Oil filter cartridge U1P113E0 book Page ...

Page 107: ...l to the O ring of the new oil filter cartridge NOTE 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 wrench 1 O ring U1P113E0 book Page 19 Friday May 19 2006 9 10 AM ...

Page 108: ...s 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 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf Recommended oil See page 10 1 Oil quantity Without...

Page 109: ...ervals specified in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oil level must be checked on a cold engine 2 Remove the final gear oil filler bolt and then check the oil level in the final gear case NOTE The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole...

Page 110: ... gear oil filler bolt and the fi nal gear oil drain bolt to drain the oil from the final gear case 5 Install the drain bolt and then tighten it to the specified torque 6 Add the recommended final gear oil to the brim of the filler hole as shown 1 Engine guard 2 Final gear case guard 3 Bolt 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf U1P113E0 bo...

Page 111: ...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 must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Place the ATV on a level surface 1 Final gear oil filler bolt 2 Correct oil level 3 Final gear oil Recommended final gear oil See page 10...

Page 112: ...en it to the specified torque 5 Add the specified amount of the recommend ed differential gear oil NOTE Do not exceed the specified differential gear oil quantity when filling Overfilling will cause the oil to seep out of the breather hose during and after riding 1 Differential gear oil filler bolt 1 Differential gear oil drain bolt Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kg...

Page 113: ...hecked before each ride In addition the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart EBU27122 To check the coolant level 1 Place the ATV on a level surface NOTE 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 NOTE The coolant should be betw...

Page 114: ...as soon as possible otherwise the cooling system will not be pro tected 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 oth erwise the effectiveness of the coolant will be reduced NOTE The radiator fan is automatically switched on or off according to the coolant temperature in the radiator If t...

Page 115: ...spilling on the footrest POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always place a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap 1 Coolan...

Page 116: ...roughly flush the cooling system with clean tap water 10 Replace the coolant drain bolt washer if it is damaged install the coolant drain bolt and then tighten it to the specified torque 11 Connect the coolant reservoir hose 12 Pour the recommended coolant into the reser voir to the maximum level mark and then in stall the reservoir cap 1 Radiator cap 1 Coolant reservoir hose Tightening torque Coo...

Page 117: ... level in the radiator If it is low add sufficient coolant until it reaches the top of the radiator and then install the radiator cap 16 Start the engine and then check for coolant leakage NOTE If any leakage is found have a Yamaha dealer check the cooling system 17 Install the panels and the front carrier EBU23630 Cleaning the air filter element The air filter element should be cleaned at the in ...

Page 118: ...nd clean the air filter element and air fil ter case 1 Remove the seat See page 4 14 2 Remove the air filter case cover by unhooking the holders 3 Pull the air filter element out of the air filter case 1 Air filter case check hose 1 Air filter case holder 2 Air filter case cover U1P113E0 book Page 30 Friday May 19 2006 9 10 AM ...

Page 119: ...ponge material from the air filter element frame 5 Wash the sponge material gently but thor oughly in solvent 1 Air filter element 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate U1P113E0 book Page 31 Friday May 19 2006 9 10 AM ...

Page 120: ...tremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine CAUTION ECB00460 Make sure that the air ...

Page 121: ...emove the bolts 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install and tighten the bolts 1 Bolt 2 Tailpipe 1 Tailpipe 2 Spark arrester U1P113E0 book Page 33...

Page 122: ...ve a Yamaha dealer check the ATV as the water may affect other engine parts POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching...

Page 123: ...e CAUTION ECB00480 The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24010 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica...

Page 124: ...ked and if necessary adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The throttle cable free play should measure 3 0 5 0 mm 0 12 0 20 in at the throttle lever Period ically check the throttle cable free play and if nec essary adjust it as follows NOTE The engine idling speed must be checked and ad justed if necessary before adjusting the throttle ca ble free ...

Page 125: ...herefore the safety system cable should be checked and adjusted at the intervals specified in the periodic maintenance and lubrication chart EBU24130 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EBU24171 Front brake pads Check each front brake pad for damage and mea sure t...

Page 126: ...he wear indi cator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set NOTE The wheels need to be removed to check the brake pads See page 8 55 EBU24261 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly causing it to become inef fective 1 Lin...

Page 127: ...stem for leakage Front brake Rear brake NOTE To check the rear brake fluid level remove panel C See page 8 9 Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking performance 1 Minimum level mark 1 Minimum level mark...

Page 128: ...aler change the brake fluid at the intervals specified in the NOTE after the peri odic maintenance and lubrication chart In addi tion have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are dam aged or leaking Oil seals Replace every two years Brake hoses Replace every four years EBU24380 Checking the front brak...

Page 129: ...ver free play should measure 0 5 2 0 mm 0 02 0 08 in as shown If the free play is in correct adjust it as follows 1 Loosen the locknut 2 Turn the brake lever free play adjusting bolt in direction a to increase the free play and in direction b to decrease it WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes op...

Page 130: ...top of the brake pedal should be positioned 72 0 mm 2 83 in above the top of the footboard If the brake pedal position is incorrect have a Yamaha dealer adjust it WARNING EWB02050 1 Locknut 2 Brake lever free play adjusting bolt 1 Distance between brake pedal and footboard POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which c...

Page 131: ...r HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer 1 Front axle boot each side 1 Rear axle boot each side...

Page 132: ...effect 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direc tion a To make the brake light come on lat er turn the adjusting nut in direction b 3 Install the panel EBU24890 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cab...

Page 133: ...icated if necessary NOTE To access the brake pedal pivot remove panel B See page 8 9 POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cables can also be come frayed or kinked which could restrict the operation of controls and lead to an acci dent or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables ...

Page 134: ...lizer 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 EBU25040 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte nance and lubrication chart EBU250...

Page 135: ... This model is equipped with a sealed type MF battery which does not require any maintenance There is no need to check the electrolyte or to add distilled water Check and if necessary tighten the battery lead connections CAUTION ECB00620 Never attempt to remove the battery cell seals as this would permanently damage the battery Recommended lubricant Lithium soap based grease 1 Grease nipple Recomm...

Page 136: ...properly connect the battery leads to the battery terminals POTENTIAL HAZARD Failure to handle batteries or battery electro lyte carefully WHAT CAN HAPPEN You could be poisoned You could be se verely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gas es HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies ...

Page 137: ...constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a constant voltage battery charg er have a Yamaha dealer charge your bat tery EBU25313 Replacing a fuse 1 Positive battery terminal 2 Negative battery terminal 1 Main fuse 2 Fuse box U1P113E0 book Page 49 Friday May 19 2006 9 10 AM ...

Page 138: ...s blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits 1 Main fuse 2 Spare main fuse 1 Headlight fuse 2 Ignition fuse 3 Auxiliary DC jack fuse 4 Four wheel drive motor fuse 5 Signaling system fuse 6 Spare fuse U1P113E0 book Page 50 Friday May 19 2006 9 10 AM ...

Page 139: ...adlight bulb If a headlight bulb burns out replace it as follows 1 Remove the bulb holder cover at the rear of the headlight by pulling it off Specified fuses Main fuse 30 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 Auxiliary DC jack fuse 10 0 A POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damag...

Page 140: ...adlight bulb cannot be removed from the headlight bulb holder To replace the headlight bulb replace the headlight bulb holder assembly WARNING EWB02180 1 Cover at the rear of the headlight 1 Headlight coupler 1 Headlight bulb holder assembly POTENTIAL HAZARD A headlight bulb is hot when it is on and im mediately after it is turned off U1P113E0 book Page 52 Friday May 19 2006 9 10 AM ...

Page 141: ...5 Connect the headlight coupler 6 Install the headlight bulb holder cover at the rear of the headlight CAUTION ECB00670 Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 7 Adjust the headlight beam if necessary EBU25550 Adjusting a headlight beam CAUTION ECB00690 It is advisable to have a Yamaha dealer make this adjustment WHAT CAN HAPPEN You can...

Page 142: ...tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the tail brake light assembly by re moving the nuts together with the washers 2 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Headlight beam adjusting screw 1 Tail brake light assembly 2 Nut U1P113E0 book Page 54 Friday May 19 2006 9 10 AM ...

Page 143: ... stops 5 Install the bulb holder together with the bulb by turning it clockwise 6 Install the tail brake light assembly by install ing the washers and the nuts EBU25650 Removing a wheel 1 Loosen the wheel nuts 1 Tail brake light assembly 2 Tail brake light bulb holder 1 Tail brake light bulb holder 2 Tail brake light bulb U1P113E0 book Page 55 Friday May 19 2006 9 10 AM ...

Page 144: ... Installing a wheel 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side to wards the wheel 1 Wheel nut 1 Arrow mark U1P113E0 book Page 56 Friday May 19 2006 9 10 AM ...

Page 145: ... the ground 3 Tighten the wheel nuts to the specified torques 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U1P113E0 book Page 57 Friday May 19 2006 9 10 AM ...

Page 146: ...cians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02260 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explo...

Page 147: ...ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is go...

Page 148: ...e engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap 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 coolan...

Page 149: ...terioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach place...

Page 150: ...carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug POTENTIAL HAZARD Operatio...

Page 151: ...l levers and pedals 7 Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a...

Page 152: ...nclined single cylinder Displacement 401 0 cm Bore stroke 84 5 71 5 mm 3 33 2 81 in Compression ratio 10 50 1 Starting system Electric and recoil starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Without oil filter cartridge replacement 2 30 L 2 43 US qt 2 02...

Page 153: ...el Recommended fuel Unleaded gasoline only Fuel tank capacity 15 0 L 3 96 US gal 3 30 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BSR33 x 1 Spark plug s Manufacturer model NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction syste...

Page 154: ...250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm Front wheel Wheel type Panel wheel Rim size 12 x 6 0AT Rear wheel Wheel type Panel wheel Rim size 12 x 7 5AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4...

Page 155: ...t Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 Meter lighting 14 V 3 0 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Coolant temperature warning light 12 V 1 7 W 1 Park indicator light 12 V 1 7 W 1 On command four wheel drive indicator light 12 V 1 7 W 1 Fuses Main fuse 30 0 A Headlight fuse 1...

Page 156: ...f erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key i...

Page 157: ...el label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number front left side 1 Model label U1P113E0 book Page 2 Friday May 19 2006 9 10 AM ...

Page 158: ...rpose of noise control prior to its sale or delivery to the ul timate 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 ...

Page 159: ...t 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 1 320 200 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 U1...

Page 160: ...ubsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also w...

Page 161: ...nd 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 m...

Page 162: ...le 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 150 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 lod...

Page 163: ... costs less within the first 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 Primary ID number your frame 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 potential hazard that could result in serious injury or death WARNING U1...

Page 164: ...11 9 11 EBU26132 U1P113E0 book Page 9 Friday May 19 2006 9 10 AM ...

Page 165: ...8 35 Carrier front 4 16 Carrier rear 4 17 Chassis fasteners 5 9 Cleaning 9 1 Coolant 5 4 8 25 Coolant temperature warning light 4 2 D Differential gear oil 5 4 Differential gear oil changing 8 23 Drive select lever 4 9 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 37 Drive shaft universal joint lubricating 8 46 E Engine break in 6 5 Engine cold st...

Page 166: ...g on a slope 6 6 Part locations 3 1 Pre operation check list 5 1 R Recoil starter 4 10 Reverse indicator light 4 2 Riding your ATV 7 1 S Safety information 1 1 Seat 4 14 Shock absorber assemblies adjusting the front and rear 4 17 Spark arrester cleaning 8 33 Spark plug checking 8 14 Specifications 10 1 Speed limiter 4 7 Speedometer 4 3 Stabilizer bushes checking 8 46 Starter choke 4 14 Start switc...

Page 167: ...ug 8 34 V belt cooling duct check hose 8 34 Vehicle identification number 11 1 W Warranty extended 11 7 Warranty limited 11 5 Wheel bearings checking 8 46 Wheel installing 8 56 Wheel removing 8 55 U1P113E0 book Page 3 Friday May 19 2006 9 10 AM ...

Page 168: ...ling and control 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 RO...

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