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Yamaha YFM7FGX, Owner'S Manual

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Yamaha YFM7FGX Owner'S Manual Download Page 95

8-2

8

The service information included in this manual
and the tools provided in the owner’s tool kit are in-
tended to assist you in the performance of preven-
tive maintenance and minor repairs. However,
additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.

NOTE:

If you do not have the tools or experience required
for a particular job, have a Yamaha dealer perform
it for you.

WARNING

EWB01830

1. Owner’s manual
2. Low-pressure tire gauge

3. Owner’s tool kit

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 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 Yamaha ATV dealer.

U5C010E0.book  Page 2  Thursday, April 5, 2007  8:59 AM

Summary of Contents for YFM7FGX

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL ...

Page 2: ...EBU17091 U5C010E0 book Page 1 Thursday April 5 2007 8 59 AM ...

Page 3: ...bout 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 INSTR...

Page 4: ...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 or ...

Page 5: ...nd spark arrester 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 YFM7FGX 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 expre...

Page 6: ...switch 4 1 Speed limiter 4 14 Front brake lever 4 15 Brake pedal and rear brake lever 4 15 Drive select lever 4 16 Fuel tank cap 4 16 Fuel 4 17 Seat 4 19 Storage compartments 4 19 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 operation check list 5 1 Fuel 5 4 Engine oil 5 4 Final gear oil 5 4 Dif...

Page 7: ...NCE 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 4 Removing and installing panels 8 8 Removing the radiator grills 8 20 Checking the spark plug 8 20 Engine oil and oil filter cartridge 8 22 Final gear oil 8 26 Differential gear oil 8 29 Coolant 8 31 Cleaning the air filter element 8 3...

Page 8: ...cking the stabilizer bushes 8 54 Lubricating the rear knuckle pivots 8 54 Lubricating the steering shaft 8 55 Battery 8 55 Replacing a fuse 8 57 Replacing a headlight bulb 8 58 Adjusting a headlight beam 8 61 Replacing the tail brake light bulb 8 61 Removing a wheel 8 62 Installing a wheel 8 63 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise regulation 1...

Page 9: ...truc tor Contact an authorized ATV dealer or call 1 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 operate an...

Page 10: ...steep for the Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose 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 ...

Page 11: ...ce of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have 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 specified in this manual Always maintain proper tire...

Page 12: ...the ATV in another vehi cle be sure it is kept upright Otherwise fuel may leak out of the fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause inju HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some gas oline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your...

Page 13: ...2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5C010E0 book Page 1 Thursday April 5 2007 8 59 AM ...

Page 14: ...hese 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 U5C010E0 book Page 2 Thursday April 5 2007 8 59 AM ...

Page 15: ...2 U5C010E0 book Page 3 Thursday April 5 2007 8 59 AM ...

Page 16: ...2 U5C010E0 book Page 4 Thursday April 5 2007 8 59 AM ...

Page 17: ...rrester 6 Engine oil dipstick 7 Oil filter cartridge 1 Rear shock absorber assembly spring preload adjusting ring 2 Rear storage compartment and tool kit 3 Fuel tank cap cover 4 Idle adjusting screw 5 Front shock absorber assembly spring preload adjusting ring 6 Spark plug U5C010E0 book Page 1 Thursday April 5 2007 8 59 AM ...

Page 18: ...wn in this manual 1 Drive select lever 2 Rear brake lever 3 Handlebar switches 4 Rear brake fluid reservoir 5 Multifunction display 6 Front brake fluid reservoir 7 On Command four wheel drive differential gear lock switch 8 Front brake lever 9 Throttle lever U5C010E0 book Page 2 Thursday April 5 2007 8 59 AM ...

Page 19: ... 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 U5C010E0 book Page 1 Thursday April 5 2007 8 59 AM ...

Page 20: ...oes not come on have a Yamaha dealer check the electrical circuit CAUTION ECB00891 The engine may overheat if the ATV is over loaded In this case reduce the load to spec ification The engine may also overheat if mud or dirt has accumulated on the radiator i e after riding in wet terrain In this case see page 1 On Command differential gear lock indicator light DIFF LOCK 2 Low range indicator light ...

Page 21: ...ator The On Command four wheel drive indicator comes on when the On Command four wheel drive switch is set to the 4WD position The On Command differential gear lock indicator in the On Command four wheel drive indica tor also comes on when the On Command differ ential gear lock switch is set to the LOCK position NOTE Due to the synchronizing mechanism in the dif ferential gear case the four wheel ...

Page 22: ...to the LOCK position NOTE When the switch is set to LOCK the On Com mand differential gear lock indicator light will flash until the differential gear is locked EBU27291 Multifunction display The multifunction display is equipped with the fol lowing 1 CLOCK button 2 RESET button 3 SELECT button 4 Speedometer 5 Fuel meter 6 Clock Hour meter 7 Odometer Tripmeter A Tripmeter B U5C010E0 book Page 4 Th...

Page 23: ...tton and then turning the key to ON switches the display between mph and km h CLOCK HOUR CLOCK To set the clock 1 Set the display to the clock mode 2 Push the SELECT button and RESET but ton together for at least three seconds 3 When the hour digits start flashing push the RESET button to set the hours 4 Push the SELECT button and the minute digits will start flashing 5 Push the RESET button to se...

Page 24: ...vice This model is equipped with a self diagnosis de vice for various electrical circuits If any of those circuits are defective the multifunc tion display will indicate a two digit error code If the multifunction display indicates such an error code note the code number and then have a Yamaha dealer check the vehicle CAUTION ECB00810 1 Fuel level warning indicator 2 Fuel meter 3 E segment 1 Error...

Page 25: ... 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 the starter motor will not operate properly If this s...

Page 26: ...s the speed limiting function While the override switch is pushed the segments of the speedometer digits will appear as shown in 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 POTENTIA...

Page 27: ...n 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 enough turn for...

Page 28: ...wheels turn at the same speed POTENTIAL HAZARD 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...

Page 29: ... 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 U5C...

Page 30: ...nging 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 WHAT CAN HAPPEN All wheels tu...

Page 31: ...tle 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 Ma...

Page 32: ...ottle 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 before riding the ATV Consult a Yamaha dealer if you can t find or solve the proble...

Page 33: ...ebar 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 t...

Page 34: ...e low range high range neutral reverse and park positions See the Operating the drive select lever and driving in reverse section on page 6 3 for the drive select lever operation EBU27350 Fuel tank cap 1 Brake pedal 1 Drive select lever U5C010E0 book Page 16 Thursday April 5 2007 8 59 AM ...

Page 35: ...click is heard and then close the fuel tank cap cover EBU18730 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap cover 1 Fuel level 2 Fuel tank filler tube U5C010E0 book Page 17 Thursday April 5 2007 8 59 AM ...

Page 36: ...use damage to the fuel system or ATV performance problems WARNING EWB00270 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal 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 fue...

Page 37: ...d push down on the seat at the EBU27361 Storage compartments This ATV is equipped with two storage compart ments The front storage compartment is located at the front right side of the ATV To access the storage compartment remove the storage compartment cover by turning it counterclockwise 1 Seat 2 Seat lock lever 1 Projection 2 Seat holder U5C010E0 book Page 19 Thursday April 5 2007 8 59 AM ...

Page 38: ... is located under the seat See page 4 19 To access the storage com partment remove the storage compartment cover 1 Front storage compartment cover 1 Rear storage compartment cover U5C010E0 book Page 20 Thursday April 5 2007 8 59 AM ...

Page 39: ...ents If they must be stored wrap them in appropriate Do not exceed the load limit of 0 5 kg 1 lb for the front storage compartment or 2 0 kg 4 lb for the rear storage compartment Do not exceed the maximum load of 220 0 kg 485 lb for the ATV NOTE A drain plug is fitted at the bottom of each storage compartment If any water collects in a storage compartment remove the drain plug drain the wa ter and...

Page 40: ...ar shock ab sorber assemblies The spring preload can be adjusted to 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 1 Storage compartment drain plug 1 Spring preload adjus...

Page 41: ...k should only be used when the engine is running 1 Set the light switch to OFF 1 Special wrench Spring preload setting Minimum soft 1 Standard 3 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 absorber assem blies on the left ...

Page 42: ...es are used without the engine running or with the headlights turned on the battery will lose its charge and engine start ing may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged WARNING EWB00010 1 Auxiliary DC jack cap Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A U5C010E0 book Page 24 ...

Page 43: ...ne which service should be performed by a Yamaha dealer 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 inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedur...

Page 44: ... add recommended brake fluid to specified level if necessary Check hydraulic system for leakage Correct if necessary 5 5 8 45 8 47 8 48 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check pedal 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 specifi...

Page 45: ... Axle boots Check for cracks or damage and replace if necessary 8 51 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 U5C010E0 book Page 3 Thursday April 5 2007 8 59 AM ...

Page 46: ...t 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 the fuel tank Be careful...

Page 47: ... 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 provide proper braking performance check th...

Page 48: ... 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 of this ATV with improper or uneven tire pressure may cause loss of control in creasi...

Page 49: ...s 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 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 kg...

Page 50: ...he 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 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 ps...

Page 51: ...ll 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 U5C010E0 book Page 9 Thursday April 5 2007 8 59 AM ...

Page 52: ...t 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 an accident or collision ...

Page 53: ...conditions The drive select lever is in the neutral or park po sition The rear brake lever or brake pedal is applied 4 Completely close the throttle lever and start the engine by pushing the start switch NOTE If the engine fails to start release the start switch then push it again Pause a few seconds before the next attempt Each cranking should be as short as possible to preserve battery energy Do...

Page 54: ...omplete stop 2 Apply the brake pedal and then shift by mov ing the drive select lever along the shift guide NOTE Make sure that the drive select lever is completely shifted into position 3 Release the brake pedal and then open the throttle lever gradually Shifting Neutral to Reverse and Reverse to Park 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park U5C010E0 book...

Page 55: ...n the throttle lever gradually and continue to watch to the rear while backing WARNING EWB00660 EBU20682 Engine break in 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or even a person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into rever...

Page 56: ... 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 throttle position 160 320 km 100 200 mi or 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine freely but do not use full throttle at any CAUTION ECB00220 If any engine trouble should occur during the engine break in period im...

Page 57: ...n Yamaha accessories nor control over their qual ity or suitability Choose a genuine Yamaha ac cessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which 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 HOW TO AVOID THE HAZARD Avoid parki...

Page 58: ...ollowing 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 bath MAXIMUM LOADING LIMIT ATV loading limit total weight of rider cargo accessories and tongue 220 0 kg 485 lb Front carrier 45 0 kg 99 lb Rear carrier 85 0 kg 187 lb Front storage compartment 0 5 kg 1 lb Rear storage compartm...

Page 59: ...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 WARNING EWB00750 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death POTENTIAL HAZARD Overloading thi...

Page 60: ...7 EBU21131 RIDING YOUR ATV U5C010E0 book Page 1 Thursday April 5 2007 8 59 AM ...

Page 61: ...g your ATV requires special skills acquired through 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...

Page 62: ...for 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 co...

Page 63: ...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 U5C010E0 book Page 4 Thursday April 5 2007 8 59 AM ...

Page 64: ...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 U5C010E0 book Page 5 Thursday April 5 2007 8 59 AM ...

Page 65: ...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 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 ...

Page 66: ... drugs WHAT CAN HAPPEN Could seriously affect your judgment 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 inspect your ATV each time you use it to make ...

Page 67: ... 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 of t...

Page 68: ...es top speed See page 4 14 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 ...

Page 69: ...dent 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 U5C010E0 book Page 10 Thursday April 5 2007 8 59 AM ...

Page 70: ...e your ability to control the ATV 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 whee...

Page 71: ...h in some situations could 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 U5C010E0 book Page 12 Thursday April...

Page 72: ...em WHAT CAN HAPPEN Dry grass or brush or other combustible ma terial 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 exhau...

Page 73: ...eways 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 U5C010E0 book Page 14 Thursday April 5 2007 8 59 AM ...

Page 74: ... 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 POTENTIAL HAZARD Failure to use extra care when operating on excessively roug...

Page 75: ...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 U5C010E0 book Page 16 Thursday April 5 2007 8 59 AM ...

Page 76: ...ithout getting per mission Select a large flat area off road to become familiar with your ATV Make sure that this area is free of obstacles and other riders You should practice control of the throttle brakes shifting procedures POTENTIAL HAZARD Operating in areas where you might not be HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch carefully for other...

Page 77: ...high range posi tion Apply the throttle 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 ...

Page 78: ...ou 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 cau...

Page 79: ...h 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 side of the turn to avoid tipping over Remember Avoid higher speeds until you...

Page 80: ...s 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 AVOID THE HAZARD Always follow proper procedures for climb ing hills as described in this Owner s Manu al Always check t...

Page 81: ...7 U5C010E0 book Page 22 Thursday April 5 2007 8 59 AM ...

Page 82: ... 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 any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of...

Page 83: ...NING EWB01351 POTENTIAL HAZARD Stalling rolling 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 If you begin rolling backwards Keep weight uphill 2WD Never apply the rear brake while roll ing backwards Apply the front ...

Page 84: ...e or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal 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 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 faste...

Page 85: ...7 U5C010E0 book Page 26 Thursday April 5 2007 8 59 AM ...

Page 86: ...ur ATV does begin to tip over gradually 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 HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as...

Page 87: ...7 U5C010E0 book Page 28 Thursday April 5 2007 8 59 AM ...

Page 88: ...50 Test your brakes after leaving the water Do not continue to ride 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 wat...

Page 89: ...of the air filter case Also re move the drain plugs from the front and rear storage compartments and the V belt case to drain any water that may have accumulated Wash the ATV with fresh water if it has been operated in salt water or muddy conditions 1 Air filter case check hose U5C010E0 book Page 30 Thursday April 5 2007 8 59 AM ...

Page 90: ...e damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult EWB01160 1 Storage compartment drain plug 1 V belt case drain plug U5C010E0 book Page 31 Thursday April 5 2007 8 59 AM ...

Page 91: ...s positioning your weight over the front wheels will sometimes help 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 obstacles always follow proper procedures as described in the Owner s...

Page 92: ...e WARNING EWB01170 WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding tech niques completely POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by pract...

Page 93: ... 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 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance ...

Page 94: ...ING 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...

Page 95: ...rating 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 to this ATV should be genuine Yamaha or equivalent compo nent...

Page 96: ... by a Yamaha dealer as they require 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 C...

Page 97: ... Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake pedal 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 ...

Page 98: ...eplace if necessary 13 Rear knuckle pivots Lubricate with lithium soap based grease 14 Steering shaft Lubricate with lithium soap based grease 15 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 16 Engine mount Check for cracks or other damage and replace if necessary 17 Axle boots Check for cracks or other damage and replace if necessary Change...

Page 99: ...le Check operation and adjust or replace if neces sary 25 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 26 Front and rear brake switches Check operation and correct if necessary Check operation and correct if necessary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whiche...

Page 100: ...lic 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 U5C010E0 book Page 7 Thursday April 5 2007 8 59 AM ...

Page 101: ...g and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed 1 Panel A 2 Panel B 3 Panel C 4 Panel D 5 Panel F 6 Panel G U5C010E0 book Page 8 Thursday April 5 2007 8 59 AM ...

Page 102: ... Panel A To remove the panel Pull upward on the areas shown To install the panel Place the panel in the original position 1 Panel E 2 Panel H 3 Panel I 1 Panel A U5C010E0 book Page 9 Thursday April 5 2007 8 59 AM ...

Page 103: ...nel 1 Remove panel A 2 Remove the front carrier by removing the bolts 3 Remove the front carrier stays by removing the bolts 1 Carrier bolt under the fenders 1 Carrier bolt top U5C010E0 book Page 10 Thursday April 5 2007 8 59 AM ...

Page 104: ... pull the panel upward to remove it To install the panel 1 Place the panel in the original position and then install the quick fasteners 1 Front carrier stay bolt 1 Panel B 2 Quick fastener U5C010E0 book Page 11 Thursday April 5 2007 8 59 AM ...

Page 105: ...tall panel A Panel C To remove the panel 1 Remove the seat See page 4 19 2 Remove panel A 3 Remove the quick fastener screws and then pull the panel upward to remove it Tightening torque Front carrier stay bolt 34 Nm 3 4 m kgf 24 ft lbf Tightening torques Carrier bolt top 26 Nm 2 6 m kgf 19 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf U5C010E0 book Page 12 Thursday April 5 2007 ...

Page 106: ...all panel A 3 Install the seat Panels D and E To remove one of the panels 1 Remove panel C 2 Remove the quick fastener screw and bolt and then pull the panel upward to remove it NOTE To ease removal of panel D shift the drive select 1 Panel C 2 Quick fastener screw U5C010E0 book Page 13 Thursday April 5 2007 8 59 AM ...

Page 107: ...8 1 Panel D 2 Quick fastener screw 1 Panel E 2 Quick fastener screw U5C010E0 book Page 14 Thursday April 5 2007 8 59 AM ...

Page 108: ...he original position and then install the bolt and quick fastener screw Panel F To remove the panel Pull outward on the areas shown To install the panel Place the panel in the original position 1 Panel F U5C010E0 book Page 15 Thursday April 5 2007 8 59 AM ...

Page 109: ...G and H To remove one of the panels Remove the nut and bolts and then pull the panel downward while pushing the projection 1 Panel G 2 Nut 3 Bolt 4 Projection U5C010E0 book Page 16 Thursday April 5 2007 8 59 AM ...

Page 110: ...8 To install one of the panels Place the panel in the original position and then in stall the bolts and nut 1 Panel H 2 Nut 3 Bolt 4 Projection U5C010E0 book Page 17 Thursday April 5 2007 8 59 AM ...

Page 111: ...the rear carrier by removing the bolts 3 Remove the quick fasteners and then push inward on the areas shown 1 Carrier bolt under the fenders 1 Carrier bolt lower U5C010E0 book Page 18 Thursday April 5 2007 8 59 AM ...

Page 112: ... carrier by installing the bolts and tightening them to the specified torques 1 Panel I 2 Quick fastener Tightening torques Carrier bolt upper 53 Nm 5 3 m kgf 38 ft lbf Carrier bolt lower 53 Nm 5 3 m kgf 38 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf U5C010E0 book Page 19 Thursday April 5 2007 8 59 AM ...

Page 113: ...ark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in 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 the spark plug cap 1 Rad...

Page 114: ...al color when the ATV is ridden normally NOTE 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 plug wrench Specified spark plug NGK CPR7EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in U5C010E0 book ...

Page 115: ...e specified torque as soon as possible 4 Install the spark plug cap EBU27461 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 Place the ATV on a level surface 2 Check the en...

Page 116: ...OTE The engine oil should be between the minimum and maximum level marks 6 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 7 Insert the dipstick completely into the oil filler hole 1 Dipstick 1 Maximum level mark 2 Minimum level mark U5C010E0 book Page 23 Thursday April 5 2007 8 59 AM ...

Page 117: ...e page 8 8 3 Place an oil pan under the engine to collect the used oil 4 Remove the dipstick and then remove the en gine oil drain bolt to drain the oil from the crankcase NOTE Skip steps 5 9 if the oil filter cartridge is not being replaced 5 Remove panel G See page 8 8 6 Remove the oil filter cartridge with an oil filter wrench NOTE 1 Oil filter cartridge 2 Oil filter wrench U5C010E0 book Page 2...

Page 118: ...d then tighten it to the specified torque with a torque wrench 9 Install panel G 10 Install the engine oil drain bolt and then tight en it to the specified torque 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque U5C010E0 book Page 25 Thursday April 5 2007 8 59 AM ...

Page 119: ...ately turn the engine off and check for the cause 13 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 14 Install panel F EBU27302 Final gear oil The final gear case must be checked for oil leak age before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In ad dition the final gear oil level must be checked and the...

Page 120: ...filler bolt and then 4 Install the oil level check bolt and oil filler bolt and then tighten them to the specified torques To change the final gear oil 1 Final gear oil 2 Final gear oil level check bolt 3 Correct oil level 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 U5C010E0 book Pag...

Page 121: ...and then tighten it to the specified torque CAUTION ECB00420 Be sure no foreign material enters the final gear case 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil 2 Final gear oil level check bolt 3 Correct oil level Recommended final gear oil See page 10 1 U5C010E0 book Page 28 Thursday April 5 2007 8 59 AM ...

Page 122: ...ion chart To check the differential gear oil level 1 Place the ATV on a level surface NOTE 2 Remove the differential gear oil filler bolt and then check the oil level in the differential 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 add sufficient oil of the recommended type to raise Tightening torques Final gear oil level c...

Page 123: ... the oil from the differential gear case 5 Add the recommended differential gear oil to the brim of the filler hole as shown Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 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 differential gear oil U5C01...

Page 124: ...ide In addition the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart EBU27122 To check the coolant level 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 between the minimum and maximum level marks Tightening torq...

Page 125: ...em 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 the engine overheats see page 8 65 for fur ther...

Page 126: ...pilling on the engine guard 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 Coo...

Page 127: ...ng the coolant thoroughly flush the cooling system with clean tap water 9 Replace the coolant drain bolt washer if it is damaged install the coolant drain bolt and then tighten it to the specified torque 1 Radiator cap 1 Coolant reservoir hose Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf U5C010E0 book Page 34 Thursday April 5 2007 8 59 AM ...

Page 128: ...fectiveness of the coolant will be reduced 13 Loosen the water pump air bleed bolt without removing it to allow all of the air to escape from the air bleed bolt hole 14 When coolant begins to flow out of the bolt Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol antifreeze con taining corrosion inhibitors for aluminum en gines Coolant quantity Radiator capacity...

Page 129: ...ten the cylinder head air bleed bolt to the specified torque 19 Start the engine and let it idle for ten minutes 20 Rev the engine five times Tightening torque Water pump air bleed bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 V belt cooling duct 2 Clamp screw 1 Cylinder head air bleed bolt Tightening torque Cylinder head air bleed bolt 10 Nm 1 0 m kgf 7 2 ft lbf U5C010E0 book Page 36 Thursday April 5 2007 8 ...

Page 130: ... belt cooling duct and then tighten the clamp screw 25 Install the panels EBU27452 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 the panels Check the hoses periodically and if dust or water collects i...

Page 131: ...e air filter case cover by unhooking the holders 3 Remove the sponge material and the mesh from the air filter case 1 Air filter case check hose 1 Air filter case holder 2 Air filter case cover U5C010E0 book Page 38 Thursday April 5 2007 8 59 AM ...

Page 132: ...erial and let it dry CAUTION ECB00440 Do not twist the sponge material when squeez ing it 7 Check the sponge material and replace it if 1 Sponge material 2 Air filter mesh POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material U5C010E0 book Page 39 Thursday April 5 2007 8 59 AM ...

Page 133: ...o the throttle body and the rubber joint mani fold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air en tering the engine CAUTION ECB00760 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 engine causing rapid...

Page 134: ...ark arrester portion of the tailpipe and inside of the tailpipe housing 4 Install the gasket and then insert the tailpipe into the muffler and align the bolt holes 5 Install the bolts and tighten them to the speci fied torque 1 Bolt 1 Tailpipe 2 Spark arrester 3 Gasket Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf U5C010E0 book Page 41 Thursday April 5 2007 8 59 AM ...

Page 135: ...ENTIAL HAZARD Improperly purging the exhaust system 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 purging the exhaust system Always let the exhaust system cool prior to touching exhaust components Always wear eye protection and make sure no one is behind the ...

Page 136: ...ostic tachometer is needed to make this adjustment 1 Start the engine and warm it up NOTE The engine is warm when it quickly responds to the throttle 2 Remove panel C See page 8 8 3 Attach the tachometer to the spark plug lead 4 Check the engine idling speed and if neces sary adjust it to specification by turning the idle adjusting screw To increase the engine idling speed turn the idle adjusting ...

Page 137: ...y 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 play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle ca...

Page 138: ...d in the periodic maintenance and lubrication chart EBU27470 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 Each brake pad is provided with a wear indicator groove which al lows you to check the brake pad wear without hav ing to disassemble the brake If a brake pad has worn ...

Page 139: ...odic maintenance and lubrication chart Each brake hose protector is provided with a wear indicator If a protector wears to the point that its indicator be comes visible have a Yamaha dealer replace the protector NOTE The wheels need to be removed to check the brake hose protectors See page 8 62 1 Wear indicator groove U5C010E0 book Page 46 Thursday April 5 2007 8 59 AM ...

Page 140: ...ly causing it to become inef fective Before riding check that the brake fluid is above the minimum level mark and replenish if neces Front brake Rear brake 1 Rear brake hose protector 2 Wear indicator 3 Protector is normal 4 Protector is worn 1 Minimum level mark U5C010E0 book Page 47 Thursday April 5 2007 8 59 AM ...

Page 141: ...for the brake fluid level to gradually go down However if the EBU24290 Changing the brake fluid Have a Yamaha dealer 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...

Page 142: ...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 U5C...

Page 143: ...dal free play should measure 0 0 5 0 mm 0 00 0 20 in as shown If the free play is in correct adjust it as follows 2 Loosen the locknut 3 Turn the brake pedal free play adjusting nut in direction a to increase the free play and in direction b to decrease it 4 Tighten the locknut 5 Install the panel If the correct free play cannot be obtained have a Yamaha dealer adjust it 1 Locknut 2 Brake pedal fr...

Page 144: ...heck the axle boots for tears or damage If any damage is found have them re placed by a Yamaha dealer 1 Distance between brake pedal and footrest 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 s...

Page 145: ...s not move smoothly have a Yamaha dealer check or replace it WARNING EWB02120 1 Front axle boot each side Recommended lubricant Engine oil 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 U5C010E0 book Page ...

Page 146: ...lubricated if necessary Front brake lever Rear brake lever EBU24951 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary NOTE To access the brake pedal pivot remove panel H See page 8 8 Recommended lubricant Silicone grease U5C010E0 book Page 53 Thursday April 5 2007 8 59 AM ...

Page 147: ...a dealer check the wheel hub bear ings EBU25021 Checking the stabilizer bushes Have a Yamaha dealer replace the stabilizer bush es if necessary EBU25051 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the pivoting points using a grease gun Recommended lubricant Lithium soap based g...

Page 148: ...ed lubricant Lithium soap based grease 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 Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of ...

Page 149: ...s fully charged 1 Place the battery in its compartment 2 Make sure to properly connect the battery leads to the battery terminals CAUTION ECB00630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a spe cial constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If y...

Page 150: ...use is blown replace it as follows 1 Fuse box 2 Spare main fuse 3 Main fuse 4 Fuel injection system spare fuse 5 Fuel injection system fuse 1 Ignition fuse 2 Headlight fuse 3 Four wheel drive motor fuse 4 Radiator fan fuse 5 Signaling system fuse 6 Auxiliary DC jack fuse 7 Spare fuse U5C010E0 book Page 57 Thursday April 5 2007 8 59 AM ...

Page 151: ... 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 40 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A Signaling system fuse 5 0 A Auxiliary DC jack fuse 15 0 A Radiator fan fuse POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage...

Page 152: ...move the headlight bulb cover 4 Unhook the headlight bulb holder and then remove the defective bulb 1 Cover at the rear of the headlight 1 Headlight coupler U5C010E0 book Page 59 Thursday April 5 2007 8 59 AM ...

Page 153: ...bulb life will be adversely affect ed Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth 1 Headlight bulb holder 2 Headlight bulb 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 1 Do not touch the gla...

Page 154: ...r make this adjustment To raise a headlight beam turn the adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25640 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove panel I See page 8 8 2 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Headlight beam adjusting scr...

Page 155: ... 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 2 Elevate the ATV and place a suitable stand 1 Tail brake light bulb holder 1 Wheel nut U5C010E0 book Page 62 Thursday April 5 2007 8 59 AM ...

Page 156: ...are used for both the front and rear wheels Install the nuts with their tapered side to wards the wheel 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques 1 Arrow mark 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 U5C010E0 book Page 63 Thursday April 5 2007 8 59 AM ...

Page 157: ...o 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 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame HO...

Page 158: ... the electric starter 2 Compression There is compression There is no compression Check the ignition Have a Yamaha dealer check the 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 Check the battery 4 Battery Dry Wet Operate the electric starte...

Page 159: ...he 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 See NOTE Start the engine If the engine overheats again have a Yamaha dealer ...

Page 160: ...CB00710 Excessive water pressure may cause water 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 Rinse the ATV off immediately with clean wa ter and dry all surface...

Page 161: ...dd fuel stabilizer if available to prevent the fuel from deteriorat ing 3 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping abil ity increasing the chance of an acciden...

Page 162: ...s and the pivoting points of all levers and pedals 5 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 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery an...

Page 163: ...il and fuel 294 0 kg 648 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Compression ratio 9 20 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 YAMALUBE 4 CW 5W30 or SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20...

Page 164: ... qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount Manufacturer MIKUNI Spark plug s Manufacturer model NGK CPR7EA 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 Shaft drive Sec...

Page 165: ...and tongue Tire air pressure measured on cold tires Recommended Front 35 0 kPa 5 0 psi 0 350 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 f...

Page 166: ...gneto Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Headlight Bulb type Tail brake light 12 V 5 0 21 0 W Meter lighting EL Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Engine trouble 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 l...

Page 167: ...10 Ignition fuse 10 0 A Auxiliary DC jack fuse 15 0 A Four wheel drive motor fuse 10 0 A Radiator fan fuse 15 0 A U5C010E0 book Page 5 Thursday April 5 2007 8 59 AM ...

Page 168: ...ef 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 1 Key identifica...

Page 169: ...0 Model label The model 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 1 Vehicle identification number front left side 1 Model label U5C010E0 book Page 2 Thursday April 5 2007 8 59 AM ...

Page 170: ...e 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 Muff...

Page 171: ...e 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 U5C010...

Page 172: ...quent 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 warra...

Page 173: ... set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha ATV dealer within the co...

Page 174: ...o 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 lodging...

Page 175: ...expires You can also save money Y E S 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 U5C010E0 book Page 8 Thursday April 5 2007 8 59...

Page 176: ...11 EBU26132 U5C010E0 book Page 9 Thursday April 5 2007 8 59 AM ...

Page 177: ...and lubricating 8 52 Carrier front 4 22 Carrier rear 4 22 Chassis fasteners 5 9 Differential gear oil 5 4 8 29 Drive select lever 4 16 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 45 E Engine break in 6 4 Engine idling speed 8 43 Engine oil 5 4 Engine oil and oil filter cartridge 8 22 Engine stop switch 4 7 Engine trouble warning light 4 3 F Fina...

Page 178: ...nstalling 8 8 Park indicator light 4 3 Parking 6 5 Parking on a slope 6 5 Riding your ATV 7 1 S Safety information 1 1 Seat 4 19 Shock absorber assemblies adjusting the front and rear 4 22 Spark arrester cleaning 8 40 Spark plug checking 8 20 Specifications 10 1 Speed limiter 4 14 Stabilizer bushes checking 8 54 Starting the engine 6 1 Start switch 4 7 Steering shaft lubricating 8 55 Storage 9 2 S...

Page 179: ...Wheel hub bearings checking 8 54 Wheel installing 8 63 Wheel removing 8 62 U5C010E0 book Page 3 Thursday April 5 2007 8 59 AM ...

Page 180: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 181: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 182: ...ct 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 HELMET AND PROTECTIVE GEAR NEVER USE ON PU...

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