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Yamaha YFM66FGX, Owner'S Manual

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Yamaha YFM66FGX Owner'S Manual Download Page 96

8-1

8

EBU21646

PERIODIC MAINTENANCE AND MINOR REPAIR

EBU21660

Safety is an obligation of the owner. Periodic in-
spection, adjustment and lubrication will keep your
ATV in the safest and best operating condition
possible. The most important points of inspection,
adjustment, and lubrication are explained on the
following pages.
The intervals given in the periodic maintenance
and lubrication chart should be considered as a
general guide under normal riding conditions.
However, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORTENED.

WARNING

EWB01820

EBU27100

Owner’s manual and tool kit 

Be sure to put this owner’s manual in the plastic
bag and to always carry it as well as the owner’s
tool kit and the low-pressure tire gauge in their re-
spective compartments under the seat.

POTENTIAL HAZARD
Servicing an engine while it is running.
WHAT CAN HAPPEN
Moving parts can catch clothing or parts of
the body, causing injury.
Electrical components can cause shocks or
start fires.

HOW TO AVOID THE HAZARD
Turn off the engine when performing mainte-
nance unless otherwise specified. Have a
Yamaha dealer perform the service if you are
not familiar with maintenance work.

U23D10E0.book  Page 1  Wednesday, March 14, 2007  1:50 PM

Summary of Contents for YFM66FGX

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 23D 28199 10 LIT 11626 21 03 YFM66FGX DIC2342 ...

Page 2: ...EBU17091 U23D10E0 book Page 1 Wednesday March 14 2007 1 50 PM ...

Page 3: ...ecial 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 INSTRUCTIONS...

Page 4: ...hange 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 or c...

Page 5: ...ester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17381 AFFIX DEALER LABEL HERE YFM66FGX OWNER S MANUAL 2007 by Yamaha Motor Corporation U S A 1st edition March 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohib...

Page 6: ... 6 Throttle lever 4 12 Speed limiter 4 13 Front brake lever 4 14 Brake pedal and rear brake lever 4 14 Drive select lever 4 15 Recoil starter 4 15 Fuel tank cap 4 16 Fuel 4 16 Fuel cock 4 18 Starter choke 4 19 Seat 4 20 Storage compartment 4 21 Front carrier 4 22 Rear carrier 4 22 Adjusting the front and rear shock absorber assemblies 4 22 Auxiliary DC jack 4 23 PRE OPERATION CHECKS 5 1 Pre operat...

Page 7: ...31 SLIDING AND SKIDDING 7 32 WHAT TO DO IF 7 33 WHAT TO DO 7 33 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 16 Engine oil and oil filter cartridge 8 18 Final gear oil 8 22 Differential gear oil 8 24 C...

Page 8: ... 48 Checking the stabilizer bushes 8 48 Lubricating the rear knuckle pivots 8 48 Lubricating the steering shaft 8 49 Battery 8 49 Replacing a fuse 8 51 Replacing a headlight bulb 8 52 Adjusting a headlight beam 8 54 Replacing the tail brake light bulb 8 55 Removing a wheel 8 55 Installing a wheel 8 56 Troubleshooting 8 57 Troubleshooting charts 8 59 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 ...

Page 9: ...uld 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 Never ...

Page 10: ...bing 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 b...

Page 11: ...ast flowing 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 a...

Page 12: ...ilot 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 gas ...

Page 13: ...ust 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 U23D10E0 book Page 5 Wednesday March 14 2007 1 50 PM ...

Page 14: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U23D10E0 book Page 1 Wednesday March 14 2007 1 50 PM ...

Page 15: ...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 U23D10E0 book Page 2 Wednesday March 14 2007 1 50 PM ...

Page 16: ...2 3 2 U23D10E0 book Page 3 Wednesday March 14 2007 1 50 PM ...

Page 17: ...2 4 2 U23D10E0 book Page 4 Wednesday March 14 2007 1 50 PM ...

Page 18: ...e select lever box check hose 11 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 Battery 5 Air filter case 6 Spark plug 7 Front brake fluid reservoir 8 Front shock absorber assembly spring preload adjusting ring 9 Rear brake fluid reservoir 10 Brake pedal 11 V belt case drain plug U23D10E0 book Page 1...

Page 19: ...s shown in this manual 1 Drive select lever 2 Rear brake lever 3 Handlebar switches 4 Starter choke 5 Multifunction display 6 Main switch 7 On Command four wheel drive differential gear lock switch 8 Throttle lever 9 Front brake lever 10 Auxiliary DC jack U23D10E0 book Page 2 Wednesday March 14 2007 1 50 PM ...

Page 20: ...n switch The positions of the main switch are as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U23D10E0 book Page 1 Wednesday March 14 2007 1 50 PM ...

Page 21: ...s in the neutral position EBU17920 Coolant temperature warning light This warning light comes on when the engine over heats When this occurs during operation stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes CAUTION ECB00010 The engine may overheat if the ATV is over loaded In this case reduce the load to spec ification 1 On Command differential gear loc...

Page 22: ...and differential gear lock switch is set to LOCK the indicator will flash until the differential gear is locked EBU17970 Park indicator light This indicator light comes on when the transmis sion is in the park position EBU17980 High range indicator light This indicator light comes on when the transmis sion is in the high range position EBU17990 Low range indicator light This indicator light comes ...

Page 23: ...de ODO and the tripmeter modes A and B in the following order ODO TRIP A TRIP B ODO To reset a tripmeter select it by pushing the TRIP ODO button and then push the TRIP ODO button for at least three seconds The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel This in formation will enable you to plan future fuel stops NOTE Holding in the TRIP ODO button...

Page 24: ...minutes by pushing the M button 5 Push the button and then release it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear from F full towards E empty as the fuel level decreases When the E segment disap pears and the fuel level warning indicator flashes set the fuel cock to reserve and refuel as soon as possibl...

Page 25: ...ons on page 6 1 prior to starting the engine EBU18151 Light switch OFF Set this switch to to turn on the low beams and the taillight Set the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights CAUTION ECB00040 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to the point that ...

Page 26: ...unction While the override switch is pushed the segments of the speedometer digits will appear as shown in the figure NOTE If the digits of the speedometer appear as shown when the switch is NOT being pushed this could indicate a malfunction in the electrical system In this case take the ATV to a Yamaha dealer at the first opportunity WARNING EWB00110 1 Override switch OVERRIDE POTENTIAL HAZARD Ri...

Page 27: ...tor comes on in the multifunction display To change from four wheel drive to two wheel drive stop the ATV and push the switch in to the 2WD position WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the ATV The effort needed to turn in creases with the riding speed You may lose control and have an accident if you cannot make a sharp e...

Page 28: ...Changing from two 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 ...

Page 29: ...h in to the LOCK position When the dif ferential gear is locked the differential gear lock in dicator DIFF LOCK will come on along with the indicator in the multifunction display To release the differential gear lock stop the ATV and push the switch to the 4WD position 1 Differential gear lock lever 2 On Command four wheel drive switch 2WD 4WD 1 On Command differential gear lock switch 4WD LOCK U2...

Page 30: ...hanging from four wheel drive to differential gear lock or vice versa while moving may cause the ATV to handle differently unexpectedly This could distract the operator and increase the risk of losing control and causing an accident HOW TO AVOID THE HAZARD Always stop the ATV before changing from four wheel drive to four wheel drive differen tial gear lock or vice versa POTENTIAL HAZARD Riding too...

Page 31: ...ottle lever Once the engine is running movement of the throt tle lever will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time the hand is removed from the throttle lever Before starting the engine check the throttle to be sure it is operating smoothly ...

Page 32: ...tion b 3 Tighten the locknut WARNING EWB00190 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 the operation of the throttle lever be fore you start the engine If it does not work smoothly check for the cause Correct the problem be...

Page 33: ...lebar To apply the rear brake push down on the brake pedal or pull the brake lever toward the handlebar grip 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 ...

Page 34: ...rive select lever and driving in reverse section on page 6 3 for the drive select lever operation EBU18680 Recoil starter Firmly grasp the handle and pull slightly until en gagement can be felt Then pull forcefully being careful not to pull the rope all the way out 1 Brake pedal 1 Rear brake lever 1 Drive select lever U23D10E0 book Page 15 Wednesday March 14 2007 1 50 PM ...

Page 35: ...tom of the filler tube as shown 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 1 Fuel tank cap U23D10E0 book Page 16 Wednesday March 14 2007 1 50 P...

Page 36: ... give you long er spark plug life and reduced maintenance cost Gasohol There are two types of gasohol gasohol contain ing ethanol and that containing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ATV performance problems WARNING EWB00270 1 Fuel le...

Page 37: ... 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 the fuel tank Be careful not to spill fuel especially on the engine or ex haust pipe Wipe up any spilled fuel immedi ately Be sure the fuel tank cap is closed securely Do not...

Page 38: ...n the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke 1 Arrow mark pointing to ON 1 Arrow mark p...

Page 39: ...eat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely fitted 1 Starter choke 1 Seat 2 Seat lock lever U23D10E0 book Page 20 Wednesday March 14 2007 1 50 PM ...

Page 40: ...et any water enter the storage compartment CAUTION ECB00130 Do not store metal or sharply edged objects like tools in the storage compartment If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartment Do not exceed the load limit of 2 0 kg 4 lb for the storage compartment Do not exceed the maximum load of 220 0 kg 485 lb for the ATV 1 Projection 2...

Page 41: ...preload can be adjusted to suit the rid er s weight and the riding conditions NOTE The rear wheels need to be removed to adjust the rear shock absorber assemblies See page 8 55 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 suspensi...

Page 42: ...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 abso...

Page 43: ... 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 auxiliary D...

Page 44: ... 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 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 ITEM ROUTINE PA...

Page 45: ...ecessary 5 5 8 39 8 40 8 42 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check lever free play and adjust if necessary Check brake pads for wear and replace if necessary Check brake fluid level in reservoir and add recommended brake fluid to specified level if necessary Check hydraulic system for leakage Correct if necessary 5 5 8 39 8 40 8 43 Throttle le...

Page 46: ...7 Axle boots Check for cracks or damage and replace if necessary 8 45 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 9 Instruments lights and switches Check operation and correct if necessary 5 9 ITEM ROUTINE PAGE U23D10E0 book Page 3 Wednesday March 14 2007 1 50 PM ...

Page 47: ...ed level Add coolant as necessary See page 8 26 NOTE The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 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 ...

Page 48: ...e 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 Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provi...

Page 49: ... with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always 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 U23D10E0 book Page 6 We...

Page 50: ...d below have been approved by Yamaha Motor Co Ltd for this model Other tire combinations are not recom mended Front Manufacturer model DUNLOP KT131 Size AT25 x 8 12 Type Tubeless Rear Manufacturer model DUNLOP KT135 Size AT25 x 10 12 Type Tubeless The tires should be set to the recommend ed pressure Recommended tire pressure Front 35 0 kPa 5 0 psi 0 350 kgf cm Rear 30 0 kPa 4 3 psi 0 300 kgf cm Ch...

Page 51: ...pecifications Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 32 0 kPa 4 6 psi 0 320 kgf cm Rear 27 0 kPa 3 9 psi 0 270 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 kgf cm Higher pres...

Page 52: ... switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 35 0 kPa 5 0 psi 0 350 kgf cm Rear 30 0 kPa 4 3 psi 0 300 kgf cm Minimum Front 32 0 kPa 4 6 psi 0 320 kgf cm Rear 27 0 kPa 3 9 psi 0 270 kgf cm Maximum Front 38 0 kPa 5 5 psi 0 380 kgf cm Rear 33 0 kPa 4 8 psi 0 330 kgf cm 1 Tire wear limit U23D10E0 book Page 9 Wednesday Ma...

Page 53: ...ARD 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 a...

Page 54: ...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 the ...

Page 55: ...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 EBU20430 Operating the drive select lever and driving in reverse CAUTION ECB00...

Page 56: ...ift 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 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park 1 Drive select lever 2 L Low range 3 H H...

Page 57: ...the first 320 km 200 mi or 20 hours The various parts in the engine wear and polish themselves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided 0 160 km 0 100 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set...

Page 58: ... pedal applied shift the drive select lever to the park position 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 you must park on an incline place the ATV transversely across the incline stop the en gine shift the drive select lever to the p...

Page 59: ...h can shift position or come off 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 ...

Page 60: ...our ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trail er Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills a...

Page 61: ...rgo improperly WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an 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 U23D10E0 book Page 9 Wednesday March 14 2007 1 50 PM ...

Page 62: ...7 1 7 EBU21131 RIDING YOUR ATV U23D10E0 book Page 1 Wednesday March 14 2007 1 50 PM ...

Page 63: ...ugh practice over a period of time Take the time to learn the basic 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 Ow...

Page 64: ...ildren 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 course o...

Page 65: ...d never operate an ATV with engine size greater than 90 cc POTENTIAL HAZARD Carrying a passenger on this ATV WHAT CAN 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...

Page 66: ...ed motorcycle helmet increases your chances of a severe head injury or death in the event of an acci dent Operating without eye 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 U23D10E0 book Page 5 Wednesday March 14 2007 1 50 PM ...

Page 67: ...torcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet U23D10E0 book Page 6 Wednesday March 14 2007 1 50 PM ...

Page 68: ...ld 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 ins...

Page 69: ...s 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 7 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 8 POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of ...

Page 70: ...page 4 13 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 220 0 kg 485 lb Front carrier 45 0 kg 99 lb Rear carrier 85 0 kg 187 lb St...

Page 71: ...ident 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 U23D10E0 book Page 10 Wednesday March 14 2007 1 50 PM ...

Page 72: ... 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 CAN...

Page 73: ...e 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 U23D10E0 book Page 12 We...

Page 74: ...cumulated 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 likely t...

Page 75: ...alks 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 U23D10E0 book Page 14 Wednesday March 14 20...

Page 76: ... use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden 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 U23D10E0 book Page 15 We...

Page 77: ...action or ATV control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slip pery or loose terrain 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 U23D10E0 book Page 16 Wednesday March 14 2007 1 50 PM ...

Page 78: ... sure that this area is free of obstacles and other riders You should practice control of the throttle brakes shifting procedures and turning techniques in this area before trying more difficult terrain Always avoid riding on paved 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 AVOI...

Page 79: ...ttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds un til you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly Im p...

Page 80: ...you do so put your weight on the footboard to the out side of the turn opposite your desired direction and lean your upper body into 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 POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control ca...

Page 81: ...rform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out ...

Page 82: ...ep hills WHAT CAN HAPPEN The ATV can overturn more easily on ex tremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO ...

Page 83: ...7 22 7 U23D10E0 book Page 22 Wednesday March 14 2007 1 50 PM ...

Page 84: ... 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 an...

Page 85: ...olling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Use the proper gear and 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 bra...

Page 86: ...l will brake the wheels on the down hill side Avoid sudden application of either the front or rear brake because the wheels on the up hill 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...

Page 87: ...7 26 7 U23D10E0 book Page 26 Wednesday March 14 2007 1 50 PM ...

Page 88: ...ally 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 you h...

Page 89: ...7 28 7 U23D10E0 book Page 28 Wednesday March 14 2007 1 50 PM ...

Page 90: ...e 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 that...

Page 91: ...ng duct check hose and the drive select lever box check hose Also remove the V belt case drain plug to drain any water that may have accumulated Wash the ATV in fresh wa ter if it has been operated in salt water or mud dy conditions 1 Air filter case check hose 1 V belt cooling duct check hose left front side of ATV U23D10E0 book Page 30 Wednesday March 14 2007 1 50 PM ...

Page 92: ...sult WARNING EWB01160 1 Drive select lever box check hose 1 V belt case drain plug POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn 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 o...

Page 93: ...nt wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide U23D10E0 book Page 32 Wednesday March...

Page 94: ...lance If nec essary gradually let off the throttle and or steer to the outside of the turn See page 7 19 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See page 7 32 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have...

Page 95: ...in balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 21 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let 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 brak...

Page 96: ...UAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01820 EBU27100 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and to always carry it as well as the owner s tool kit and the low pressure tire gauge in their re spective compartments under the seat POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch ...

Page 97: ...er 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 t...

Page 98: ...re special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 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 i...

Page 99: ...ss and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U23D10E0 book Page 4 Wednesday March 14 2007 1 50 PM ...

Page 100: ... 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 replace if...

Page 101: ...ed grease 14 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 15 Engine mount Check for cracks or other damage and replace if necessary 16 Axle boots Check for cracks or other damage and replace if necessary 17 Engine oil Change Check ATV for oil leakage and correct if neces sary 18 Engine oil filter car tridge Replace 19 Differential gear oil C...

Page 102: ...peration and adjust or replace if neces sary 24 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 25 Front and rear brake switches Check operation and correct if necessary 26 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR ...

Page 103: ...orrect 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 U23D10E0 book Page 8 Wednesday March 14 2007 1 50 PM ...

Page 104: ...f the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU27052 Panels A and D To remove one of the panels 1 Remove the seat See page 4 20 2 Pull outward on the area shown and then pull upward as shown 1 Panel A 2 Panel B 3 Panel C 1 Panel D 2 Panel E 3 Panel F 4 Panel G U23D10E0 book Page 9 Wednesday March 14 2007 1 50 PM ...

Page 105: ...one of the panels 1 Insert the panel projections in the numerical order shown in the illustration and then push inward on the area shown 1 Panel A 1 Panel D 1 Panel A U23D10E0 book Page 10 Wednesday March 14 2007 1 50 PM ...

Page 106: ...e panel in the original position and install the bolts CAUTION ECB00380 When installing the panel be sure not to pinch the cables or wires Panel C To remove the panel 1 Remove the front carrier by removing the stay covers then by removing the bolts 1 Panel D 1 Panel B 2 Bolt U23D10E0 book Page 11 Wednesday March 14 2007 1 50 PM ...

Page 107: ...Remove the quick fastener screws and pull the panel upward 1 Front carrier stay cover 1 Carrier bolt top 1 Carrier bolt top 1 Carrier bolt under the fenders U23D10E0 book Page 12 Wednesday March 14 2007 1 50 PM ...

Page 108: ...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 26 Nm 2 6 m kgf 19 ft lbf Carrier bolt under fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Panel E 2 Bolt U23D10E0 book Page...

Page 109: ...lace the panel in its original position Panel G To remove the panel 1 Remove the seat See page 4 20 2 Remove the rear carrier by removing the bolts 1 Panel F 1 Carrier bolt top U23D10E0 book Page 14 Wednesday March 14 2007 1 50 PM ...

Page 110: ...position 2 Install the rear carrier by installing the bolts and tightening them to the specified torques 3 Install the seat 1 Carrier bolt under the fenders 1 Seat under bracket 2 Panel G Tightening torques Carrier bolt top 26 Nm 2 6 m kgf 19 ft lbf Carrier bolt under fenders 7 Nm 0 7 m kgf 5 1 ft lbf U23D10E0 book Page 15 Wednesday March 14 2007 1 50 PM ...

Page 111: ... panel A See page 8 9 2 Remove the spark plug cap 3 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally NOTE If the spark plug shows a distinctly different color the engine could b...

Page 112: ...specification 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK DPR8EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in 1 Spark plug gap Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf U23D10E0 book ...

Page 113: ...ls 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 Check the engine oil level on a cold engine NOTE If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil set tles for an accurate reading 4 Remove ...

Page 114: ... the panel To change the engine oil with or without oil fil ter cartridge replacement 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 min utes and then turn it off 4 Place an oil pan under the engine to collect the used oil 5 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase 1 M...

Page 115: ...s available at a nearby Yamaha dealer 8 Apply a thin coat of engine oil 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 cartridge 2 Oil filter wrench 1 O ring U23D10E0 book Page 20 Wednesday March 14 2007 1 5...

Page 116: ...l also lubricates the clutch do not mix 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 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf Recommended oil See page 10 1...

Page 117: ... the final gear oil level must be checked and the oil changed as follows at the intervals 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 level check bolt and then check the oil level in the final gear case NOTE The oil level sh...

Page 118: ...final gear oil drain bolt to drain the oil from the final gear case 4 Install the drain bolt and then tighten it to the specified torque 5 Add the recommended final gear oil to the brim of the check hole as shown 1 Final gear oil filler bolt Tightening torques Final gear oil level check bolt 10 Nm 1 0 m kgf 7 2 ft lbf Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil drain bolt...

Page 119: ...repair the ATV In addition the differential gear oil level must be checked and the oil changed as follows at the in tervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface NOTE The differential gear oil level must be checked on a cold engine 1 Final gear oil 2 Final gear oil level check bolt 3 Correct oil level...

Page 120: ...e differential gear oil 1 Place the ATV on a level surface 2 Place an oil pan under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case 4 Install the drain bolt and then tighten it to the specified torque 1 Differential gear oil 2 Differential gear oil filler bolt...

Page 121: ...level should be checked 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 Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 Differential gear oil 2 Differential gear oil filler bolt 3 Correct oil level Recommended d...

Page 122: ...not available use distilled water or soft tap water instead Do not use hard wa ter or salt water since it is harmful to the en gine If water has been used instead of coolant re place it with coolant 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 cool...

Page 123: ... the coolant drain bolt Use a trough or a similar object as shown to prevent coolant from 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 ...

Page 124: ...e the radiator cap 6 Remove panel D See page 8 9 7 Remove the coolant reservoir cap 8 Disconnect the hose on the coolant reservoir side and then drain the coolant from the cool ant reservoir 1 Trough 1 Radiator cap U23D10E0 book Page 29 Wednesday March 14 2007 1 50 PM ...

Page 125: ...p water instead Do not use hard wa ter or salt water since it is harmful to the en gine If water has been used instead of coolant re place it with coolant as soon as possible otherwise the cooling system will not be pro tected against frost and corrosion 1 Coolant reservoir hose Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Antifreeze water mixture ratio 1 1 Recommended antifreez...

Page 126: ...age NOTE If any leakage is found have a Yamaha dealer check the cooling system 17 Install the panels and the front carrier EBU23651 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas NOTE There is a check ...

Page 127: ...element out of the air filter case 4 Remove the sponge material from the air filter element frame 1 Air filter case holder 2 Air filter case cover 1 Air filter element 1 Unlock U23D10E0 book Page 32 Wednesday March 14 2007 1 50 PM ...

Page 128: ...amaha foam air filter oil or other qual ity foam air filter oil to the sponge material NOTE The sponge material should be wet but not drip ping 1 Air filter element frame 2 Sponge material POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning ...

Page 129: ...bber 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 filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the eng...

Page 130: ...e 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 WARNING EWB01910 1 Bolt 1 Tailpipe 2 Spark arrester POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system U23D10E0 book Page 35 Wednesday March 14 2007 1 50 PM ...

Page 131: ... after removing the plug have a Yamaha dealer check the ATV as the water may affect other engine parts 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 exhaust components Do not start the engine when ...

Page 132: ...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 t...

Page 133: ...d 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 pl...

Page 134: ...efore 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 the ...

Page 135: ...he brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly causing it to become inef fective Before riding check that the brake fluid is above the minimum level mark and replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake sy...

Page 136: ...ormance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fl...

Page 137: ...ter 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 brake lever free play The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart The brake lever should hav...

Page 138: ...ake 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 POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes 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 ...

Page 139: ...ear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move Checking the brake pedal position The 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 1 Locknut 2 Brake lever free play adjusting bolt 1 Distance between brake pedal and footboard ...

Page 140: ...kes 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 pe...

Page 141: ...ect 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 cables...

Page 142: ... brake lever Rear brake lever 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 Recommended lubricant Silicone grease U23D10E0 book Pag...

Page 143: ...es not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU25021 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 EBU25051 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated...

Page 144: ... 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 WARNING EWB02140 1 Grease nipple Recommended lubricant Lithium soap based grease POTENTIAL HAZARD Failure to handle batteries or battery electro lyte carefully WHAT CAN HAPPEN You could be poisoned You could be se verely bur...

Page 145: ...ry is fully charged 1 Place the battery in its compartment 2 Make sure to properly connect the battery leads to the battery terminals HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten eg...

Page 146: ...t voltage battery charg er have a Yamaha dealer charge your bat tery EBU25313 Replacing a fuse The main fuse and the fuse box are located under the seat See page 4 20 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits 1 Main fuse 2 Spare main fuse 3 Headlight fuse 4 Ignition fuse 5 Auxiliary DC jack fuse 6 Four wheel drive motor fuse 7 Signaling sys...

Page 147: ...t bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off 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 Backup fuse 10 0 A POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause dama...

Page 148: ... Cover at the rear of the headlight 1 Headlight bulb holder cover 1 Headlight bulb holder POTENTIAL HAZARD A headlight bulb is hot when it is on and im mediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it U23D10E0 book Page 53 Wednesday March ...

Page 149: ...der by pushing it in and turn ing it clockwise 7 Install the bulb holder cover and the 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 8 Adjust the headlight beam if necessary EBU25550 Adjusting a headlight beam CAUTION ECB00690 It is advisable to have a Yamaha dealer make this adjustment To r...

Page 150: ...move the defective bulb by pushing it in and turning it counterclockwise 4 Insert a new bulb into the bulb holder push it in and then turn it clockwise until it stops 5 Install the bulb holder together with the bulb by turning it clockwise 6 Install the panel EBU25650 Removing a wheel 1 Loosen the wheel nuts 1 Headlight beam adjusting screw 1 Tail brake light bulb holder U23D10E0 book Page 55 Wedn...

Page 151: ...nstalling 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 U23D10E0 book Page 56 Wednesday March 14 2007 1 50 PM ...

Page 152: ...V re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02260 1 Tapered nut Tightening torques Front wheel nut ...

Page 153: ... THE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces U23D10E0 book Page 58 Wednesday March 14 2007 1 50 PM ...

Page 154: ... 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 good ...

Page 155: ...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 coolant ...

Page 156: ...ioration 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 places 5...

Page 157: ...buretor 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 Operation w...

Page 158: ...evers 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 co...

Page 159: ...e cylinder Displacement 660 0 cm Bore stroke 100 0 84 0 mm 3 94 3 31 in Compression ratio 9 10 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 1 90 L 2 01 US qt 1 67 Imp qt 0 10 ...

Page 160: ...commended fuel Unleaded gasoline only Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount 3 5 L 0 92 US gal 0 77 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BSR42 x 1 Spark plug s Manufacturer model NGK DPR8EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system ...

Page 161: ...0 psi 0 350 kgf cm Rear 30 0 kPa 4 3 psi 0 300 kgf cm Minimum Front 32 0 kPa 4 6 psi 0 320 kgf cm Rear 27 0 kPa 3 9 psi 0 270 kgf cm Maximum Front 38 0 kPa 5 5 psi 0 380 kgf cm Rear 33 0 kPa 4 8 psi 0 330 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 flu...

Page 162: ...n 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 Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Park indicator light LED On Command four wheel drive differential gear lock indicator LCD High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Fuses Mai...

Page 163: ...10 5 10 Four wheel drive motor fuse 3 0 A U23D10E0 book Page 5 Wednesday March 14 2007 1 50 PM ...

Page 164: ...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 ide...

Page 165: ...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 U23D10E0 book Page 2 Wednesday March 14 2007 1 50 PM ...

Page 166: ...ose 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 Mu...

Page 167: ...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 U23D...

Page 168: ...sequent 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 war...

Page 169: ... 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 mac...

Page 170: ...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 lodgin...

Page 171: ...osts 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 U23D...

Page 172: ...11 9 11 EBU26132 U23D10E0 book Page 9 Wednesday March 14 2007 1 50 PM ...

Page 173: ...t 4 22 Carrier rear 4 22 Chassis fasteners 5 9 Cleaning 9 1 Coolant 5 4 8 26 Coolant temperature warning light 4 2 D Differential gear lock indicator light 4 3 Differential gear oil 5 4 8 24 Drive select lever 4 15 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 39 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 37 Engine oil 5 4 E...

Page 174: ...3 1 Pre operation check list 5 1 R Rear knuckle pivots lubricating 8 48 Recoil starter 4 15 Reverse indicator light 4 2 Riding your ATV 7 1 S Safety information 1 1 Seat 4 20 Shock absorber assemblies adjusting the front and rear 4 22 Spark arrester cleaning 8 34 Spark plug checking 8 16 Specifications 10 1 Speed limiter 4 13 Stabilizer bushes checking 8 48 Starter choke 4 19 Start switch 4 6 Stee...

Page 175: ...W Warranty extended 11 7 Warranty limited 11 5 Wheel hub bearings checking 8 48 Wheel installing 8 56 Wheel removing 8 55 U23D10E0 book Page 3 Wednesday March 14 2007 1 50 PM ...

Page 176: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 177: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 178: ... surfaces pavement may seriously affect handling 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 HELME...

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