Yamaha YFM700PF Owner'S Manual Download

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DIC183

YFM700PF/YFM700PHF/YFM700PSF

YFM700PLF/YFM700FWAD

OWNER’S MANUAL

MANUEL DU PROPRIÉTAIRE

MANUAL DEL PROPIETARIO

B38-F8199-60

READ THIS MANUAL CAREFULLY!

It contains important safety information.

LIRE ATTENTIVEMENT CE MANUEL!

Il comprend d’importantes informations de sécurité.

¡LEA ESTE MANUAL ATENTAMENTE!

Contiene indicaciones importantes acerca de la seguridad.

Summary of Contents for YFM700PF

Page 1: ... PROPRIÉTAIRE MANUAL DEL PROPIETARIO B38 F8199 60 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad ...

Page 2: ...DIC183 Original instructions Notice originale Manual original PRINTED IN USA 2014 07 0 5 1 CR E F S ...

Page 3: ...tains important safety information WARNING OWNER S MANUAL YFM700PF YFM700PHF YFM700PSF YFM700PLF YFM700FWAD This ATV should not be ridden by anyone under 16 years of age B38 F8199 60 E0 UB3860E0 book Page 1 Monday July 14 2014 10 34 AM ...

Page 4: ...jk The Netherlands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title and or number and date of issue of stan...

Page 5: ...sic understanding of the features and operation of this ATV This manual includes important safety information It provides information about 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 ...

Page 6: ... safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key info...

Page 7: ...ease check your local riding laws and regulations before operating this ATV EBU17411 YFM700PF YFM700PHF YFM700PSF YFM700PLF YFM700FWAD OWNER S MANUAL 2014 by Yamaha Motor Co Ltd 1st edition June 2014 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A UB3860E0 book Page 1 Monday July 14 2014 10 34 AM ...

Page 8: ...e lever 4 14 Drive select lever 4 15 Fuel tank cap 4 15 Fuel 4 16 Seat 4 18 Storage compartments 4 18 Front carrier 4 21 Rear carrier 4 21 Adjusting the front and rear shock absorber assemblies 4 21 Auxiliary DC jack 4 23 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Differential gear oil 5 3 Coolant 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Tires 5 4 Chassis fasteners...

Page 9: ...oving the radiator grills 8 19 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 39 Cleaning the spark arrester 8 42 V belt case drain plug 8 44 Adjusting the throttle lever free play 8 44 Valve clearance 8 45 Adjusting the drive select lever safety system cable 8 45 Brakes 8 45 Checki...

Page 10: ... Replacing a headlight bulb 8 61 Adjusting a headlight beam 8 62 Replacing the tail brake light bulb 8 63 Removing a wheel 8 64 Installing a wheel 8 64 Troubleshooting 8 65 Troubleshooting charts 8 66 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 INDEX 12 1 UB3860E0 book Page 3 Monday July 14 2014 10 34 AM ...

Page 11: ...s on your ATV 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 re placement label from your Yamaha dealer For Europe 1 23 4 5 6 7 9 8 10 11 UB3860E0 book Page 1 Monday July 14 2014 10 34 AM ...

Page 12: ...15 kgf 33 lbf 37S F817S 00 1HP F817R 10 85 kg 187 lbs 35 0 kPa 0 35 kgf cm 5 0 psi 30 0 kPa 0 30 kgf cm 4 4 psi 1HP F816M M0 YAMAHA 1HP F817R 00 45 kg 99 lbs 1P0 F816P 20 YAMAHA 1 2 3 4 5 UB3860E0 book Page 2 Monday July 14 2014 10 34 AM ...

Page 13: ...1 3 1 37S F816N 00 0 5 kg 1 lb YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWAD 34 0 kW 294 kg 2014 2BG F155A 10 YAMAHA 1HP F811R 00 6 7 8 UB3860E0 book Page 3 Monday July 14 2014 10 34 AM ...

Page 14: ...1 4 1 37S F816S 00 1P0 F816R 00 YAMAHA 9 10 11 UB3860E0 book Page 4 Monday July 14 2014 10 34 AM ...

Page 15: ... from 12 years old Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 16 Use from 16 years old Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER use on paved roads NEVER carry passengers NEVER use with drugs or alcohol NEVER store fuel or flammable...

Page 16: ...loss of control Adjust the tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all other load rel...

Page 17: ...1 7 1 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN kW kg 1 2 3 4 1 2 3 4 Year of construction Model Name Max Power Mass In Running Order UB3860E0 book Page 7 Monday July 14 2014 10 34 AM ...

Page 18: ...1 8 1 For Oceania 1 2 3 4 5 6 8 7 9 UB3860E0 book Page 8 Monday July 14 2014 10 34 AM ...

Page 19: ...0 YAMAHA MAXIMUM LOADING LIMIT 37S F151K 00 PULLING LOAD 5880 N 600 kgf 1322 lbf TONGUE WEIGHT 147 N 15 kgf 33 lbf YAMAHA WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 1 2 3 4 UB3860E0 book Page 9 Monday July 14 2014 10 34 AM ...

Page 20: ...op Avoid hills and rough terrain Maximum Vehicle Load 220 kg 485 lbs Includes weight of operator cargo and accessories and if applicable trailer tongue weight WARNING 1HP F816M 00 YAMAHA IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold LOADING TRAILER TOWING WARNING NEVER operate this AT...

Page 21: ...ruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNE...

Page 22: ...ild under 16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV This vehicle is intended for off road use only Do not operate on any paved surfaces such...

Page 23: ...ting to turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shif...

Page 24: ...h as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast 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 ar...

Page 25: ...ssary If you can physically operate your vehicle inspect your vehicle If the vehicle is in safe operating con dition and you can safely operate it restart it and ride gently back to camp or other known location where you can receive medical at tention If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If yo...

Page 26: ... the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries re lated to changes in the vehicle Keep the following guidelines in mind as well as those provided un der Loading when mounting accessories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before...

Page 27: ...o deadly levels of carbon monoxide can linger for hours or days in en closed or poorly ventilated areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run...

Page 28: ...oil dipstick 7 Oil filter cartridge 8 Coolant reservoir 5 1 Rear shock absorber assembly spring preload adjusting ring 2 Rear storage compartment and tool kit 3 Fuel tank cap cover 4 Front shock absorber assembly spring preload adjusting ring 5 Spark plug 6 Brake pedal 7 V belt case drain plug UB3860E0 book Page 1 Monday July 14 2014 10 34 AM ...

Page 29: ... 2 Rear brake lever 3 Handlebar switches 4 Horn switch 5 Rear brake fluid reservoir 6 Multi function display 7 Front brake fluid reservoir 8 On Command four wheel drive differential gear lock switch 9 Front brake lever 10 Throttle lever 11 Front storage compartment 12 Main switch 13 Auxiliary DC jack UB3860E0 book Page 2 Monday July 14 2014 10 34 AM ...

Page 30: ...e 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 UB3860E0 book Page 1 Monday July 14 2014 10 34 AM ...

Page 31: ...tor light This indicator light comes on when the transmis sion is in the reverse position EBU17971 Park indicator light This indicator light comes on when the transmis sion is in the park position 1 On Command differential gear lock indicator light DIFF LOCK 2 Low range indicator light L 3 High range indicator light H 4 Neutral indicator light N 5 Reverse indicator light R 6 Park indicator light P...

Page 32: ...ion on how to access the radiator Start the engine after making sure that the warning light is out Continuous use while the warning light is on may cause damage to the engine EBU30481 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is not work ing correctly When this occurs have a Yamaha dealer check the self diagnosis system See...

Page 33: ...ial gear lock indicator and indicator light DIFF LOCK 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 and the On Command differential gear lock indicator light DIFF LOCK come on when the On Command differential gear lock switch is set to the LOCK position TIP Due to the synchro...

Page 34: ...P A and TRIP B in the fol lowing order ODO TRIP A TRIP B ODO To reset a tripmeter select it by pushing the SE LECT button and then push the RESET 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 information will enable you to plan future fuel stops TIP Pushing and holding in the SELECT button and turning the ke...

Page 35: ...SELECT 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 disappears and the fuel level warning indicator flashes refuel as soon as possible TIP This fuel meter is equipped with a self diagnosis system If the ...

Page 36: ...play indicates an error code note the code number and then have a Yamaha dealer check the vehicle NOTICE ECB00812 If the multi function display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage EBU18062 Handlebar switches 1 Error code display 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE 5 Horn switch UB386...

Page 37: ...d 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 NOTICE ECB00044 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 should happen remove the battery and recharge it See page 8 55 EBU...

Page 38: ...ifferential gear lock and al low extra time and distance for maneuvers All wheels turn at the same speed when the dif ferential is locked so it takes more effort to turn the ATV The effort needed to turn increas es with the riding speed You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are trav eling EBU26607 On Command four wheel drive switch 2WD 4...

Page 39: ...4WD position Then the four wheel drive indicator comes on in the multi function dis play To change from four wheel drive to two wheel drive stop the ATV and push the switch in to the 2WD position EBU30462 On Command differential gear lock switch 4WD LOCK WARNING EWB00132 Always stop the ATV before changing from four wheel drive to four wheel drive differen tial gear lock or vice versa The ATV hand...

Page 40: ...ATV is equipped with a switch allowing you to lock the differential gear when in four wheel drive Select the appropriate switch position according to the terrain and the conditions 4WD four wheel drive Power is supplied to the rear and front wheels LOCK four wheel drive with the differential gear locked Power is supplied to the rear and front wheels and the differential gear is locked Unlike in fo...

Page 41: ... the switch to the 4WD position TIP When the switch is set to LOCK or 4WD the differential gear lock indicator and indicator light will flash until the differential gear is completely locked or unlocked When the indicator and indicator light are flash ing turning the handlebar back and forth will help the differential gear lock to engage or dis engage 1 Differential gear lock lever 2 On Command fo...

Page 42: ...g the throttle le ver 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 throttle lever is re leased Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the leve...

Page 43: ...operation You could lose control resulting in an accident EWB00242 3 Tighten the locknut EBU18392 Front brake lever The front brake lever is located on the right han dlebar To apply the front brake pull the brake le ver toward the handlebar grip EBU18443 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handleba...

Page 44: ...erating the drive select lever and driving in reverse section on page 6 2 for the drive select lever operation EBU27351 Fuel tank cap To remove the fuel tank cap Open the fuel tank cap cover and then remove the fuel tank cap by turning it counterclockwise 1 Brake pedal 1 Rear brake lever 1 Drive select lever UB3860E0 book Page 15 Monday July 14 2014 10 34 AM ...

Page 45: ...ing fol low these instructions 1 Before refueling turn off the engine and be sure that no one is sitting on the vehicle Nev er refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole St...

Page 46: ...or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes NOTICE ECB00071 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system 1 ...

Page 47: ...e maintenance costs EBU18882 Seat 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 Make sure that the seat is securely fitted EBU27363 Storage compartments This ATV is equipped with two storage compart ments 1 Seat 2 Seat lock lever 1 Pr...

Page 48: ...ont 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 The rear storage compartment is located under the seat See page 4 18 To access the storage compartment remove the storage compartment cover 1 Front storage compartment cover 1 Front storage compartment UB3860E0 book Page 19 Mond...

Page 49: ... 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 TIP 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 water and then install the drain plug 1 Rear storage compartment cover 1 Rear storage compartment...

Page 50: ...485 lb for the ATV EBU19147 Adjusting the front and rear shock ab sorber assemblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions WARNING EWB00401 Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac cident 1 Storage compartment ...

Page 51: ... preload and thereby soften the suspension Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 UB3860E0 book Page 22 Monday July 14 2014 1...

Page 52: ...ry off 3 Start the engine See page 6 1 4 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 5 Turn the accessory on 6 When the auxiliary DC jack is not being used cover it with the cap NOTICE ECB00121 Do not use accessories requiring more than the above maximum capacity This may overload the circuit and cause the fuse to blow 1 Auxiliary DC jack cap 1 Auxiliary ...

Page 53: ...e 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 UB3860E0 book Page 24 Monday July 14 2014 10 34 AM ...

Page 54: ...y a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 16 5 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 5 3 8 22 Final gear oil Check ATV for o...

Page 55: ...Throttle lever Make sure that operation is smooth Lubricate cable and lever housing if necessary Check lever free play and adjust if necessary 5 4 8 44 Control cables Make sure that operation is smooth Lubricate if necessary 8 52 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Brake ...

Page 56: ...sary See page 8 31 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU29083 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front and rear brake levers If there is free play have a Yamaha dealer check the brake system Check for correct free play in the brake pedal If the free play is incorrect adjust...

Page 57: ...must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19815 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use the low pressure tire gauge to check and ad just tire pressures when the tires are cold Tire pressures must be equal on both sides WARNING Op...

Page 58: ...n the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended tire pressure Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum tire pressure Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi 1 Low pressure tire gauge UB3860E0 book Page...

Page 59: ...sted below have been approved for this model by Yamaha Motor Manufacturing Corporation of America 1 Tire wear limit Front Manufacturer model YFM700FWAD MAXXIS MU19A YFM700PF CHENG SHIN C828 AUS NZL YFM700PF MAXXIS MU19A EUR FRA GBR YFM700PHF MAXXIS MU19A YFM700PLF CHENG SHIN C828 YFM700PSF CHENG SHIN C828 AUS NZL YFM700PSF MAXXIS MU19A EUR FRA GBR Size AT25 x 8 12 Type Tubeless UB3860E0 book Page ...

Page 60: ...that all nuts bolts and screws are properly tightened EBU19851 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary Rear Manufacturer model YFM700FWAD MAXXIS MU20A YFM700PF CHENG SHIN C828 AUS NZL YFM700PF MAXXIS MU20A EUR FRA GBR YFM700PHF MAXXIS MU20A YFM700PLF CHENG SHIN C828 YFM700PSF CHENG SHIN C828 AUS NZL YFM700PSF MAXXIS M...

Page 61: ... off Coolant temperature warning light Engine trouble warning light The EPS warning light should come on then go off when the engine is started NOTICE ECB00825 If a warning light does not go off see page 4 2 for the corresponding warning light circuit check To avoid possible damage do not oper ate the ATV if a warning light stays on 2 Apply the brake pedal and then shift the drive select lever int...

Page 62: ... be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt NOTICE ECB00164 For maximum engine life never accelerate hard when the engine is cold EBU20442 Operating the drive select lever and driving in reverse NOTICE ECB00171 Before shifting stop the ATV otherwise the transmission may be damaged Shifting Neutral to High range and High range to ...

Page 63: ...people or ob stacles behind you When it is safe to proceed go slowly 1 Bring the ATV to a complete stop 2 Apply the brake pedal The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal 3 Shift from neutral to reverse or from reverse to park and vice versa by moving the drive se lect lever along the shift guide 1 Drive select lever 2 L Low range 3 H Hig...

Page 64: ...ven in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various ...

Page 65: ...he engine and shift the drive select lever into the park position EBU29901 Parking on a slope WARNING EWB00861 Avoid parking on hills or other inclines Parking on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident If you must park on an incline place the ATV transversely across the incline stop the engine shift the drive select lever to the park...

Page 66: ... aftermarket products similar in design and quality to genuine Yamaha Accesso ries recognize that some aftermarket accessories or modifications are not suitable because of po tential safety hazards to you or others Installing aftermarket products or having other modifica tions performed to your ATV that change any of the vehicle s design or operation characteristics can put you and others at great...

Page 67: ...trailer can change the stability and han dling of an ATV You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable Do not exceed the maximum tongue weight You can measure tongue weight with a bath room scale Put the tongue of the loaded trailer on the scale with the t...

Page 68: ...shifting load can cause an accident Make sure the load does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavie...

Page 69: ...7 1 7 EBU21142 RIDING YOUR ATV UB3860E0 book Page 1 Monday July 14 2014 10 34 AM ...

Page 70: ...n on pages 2 1 2 6 Also read all warn ing and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01382 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types ...

Page 71: ...at are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WARNING Never carry a passenger Carrying a passenger on this ATV greatly reduces your ability to balance and contro...

Page 72: ...G Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01412 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating wi...

Page 73: ...V each time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and mainte nance procedures and schedules described in the Owner s Manual WARNING Failure to inspect the ATV before operating it and to maintain it properly increases the possibility of an acci dent or equipment damage EWB01432 Speed limiter Fo...

Page 74: ... centered side to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier vehicle ...

Page 75: ...l off of the ATV If you remove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident EWB01472 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rid er accessories and tongue 220 0 kg 485 ...

Page 76: ...the engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine ...

Page 77: ...faces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01512 While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles Watch carefully for other vehicles Make sure you UB3860E0 boo...

Page 78: ... may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01532 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary to ...

Page 79: ... flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where you cannot easily be seen Mount a cau tion flag on the ATV to make you more visible Watch carefully for other vehicles EWB01552 Do not ride in areas posted no trespassing Do not ride on private property without getting permission UB3860E0 book Page 11 Mond...

Page 80: ... release the throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident NOTICE ECB00252 Do not shift from low range to high range or vice versa without coming to a complete stop Damage to the engine or drive train may occur TURNING YOUR ATV WARNING EWB01772 Always follow proper pro...

Page 81: ...f your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throt tle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV be gins to tip over to the outside whil...

Page 82: ...suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a...

Page 83: ...f you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to...

Page 84: ...ore easily on extremely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble Improper braking can cause the wheels on the uphill side to come off the ground or cause loss of tract...

Page 85: ...ther the front or rear brake because the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01633 Im...

Page 86: ...t may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your 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 grad ually steer again in the direction you wish to travel C...

Page 87: ... ATV without verifying that you have regained proper braking ability WARNING Wet brakes may have reduced stopping ability which could cause loss of control EWB02622 After riding your ATV in water be sure to drain the trapped water by removing the check hoses at the bottom of the air filter case Also remove the drain plugs from the front and rear storage compart ments and the V belt case to drain a...

Page 88: ...7 20 7 1 Air filter case check hose 1 Air filter case check hose 1 Storage compartment drain plug 1 Storage compartment drain plug UB3860E0 book Page 20 Monday July 14 2014 10 34 AM ...

Page 89: ...tboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may result SLIDING AND SKIDDING WARNING EWB01663 Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely sli...

Page 90: ...ecommended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are reduced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost WHAT TO DO IF This se...

Page 91: ...d If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 13 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 b...

Page 92: ...rn off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 6 for more information about carbon monoxide WARNING EWB02691 B...

Page 93: ...l and the tools provided in the owner s tool kit are intended to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s manual 2 Low pressure...

Page 94: ...al 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 if necess...

Page 95: ...reed valve and hose for damage Replace any damaged parts if necessary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 UB3860E0 book Page 4 Monday July 14 2014 10 34 AM ...

Page 96: ...d with an asterisk should be performed 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 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check...

Page 97: ... and replace if nec essary 7 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 8 Wheel hub bearings Check for looseness or damage and replace if necessary 9 V belt Check for wear cracks or other damage and re place if necessary 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened NO ITEM CHECK OR ...

Page 98: ...d 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 18 Engine oil Change Check ATV for oil leakage and correct if neces sary 19 Engine oil filter car tridge Replace 20 Differential gear oil Change Check ATV for oil leakage and correct if neces sary NO ITEM CHECK OR M...

Page 99: ...lace if neces sary 25 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 26 Front and rear brake switches Check operation and correct if necessary 27 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320...

Page 100: ...t full throttle Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged UB3860E0 book Page 9 Monday July 14 2014 10 34 AM ...

Page 101: ...jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU27388 Panel A To remove the panel Pull upward on the areas shown 1 Panel A 2 Panel B 3 Panel C 4 Panel D 5 Panel F 1 2 3 5 4 1 Panel E 2 Panel G 3 Panel H 1 3 2 UB3860E0 book Page 10 Monday July 14 2014 10 34 AM ...

Page 102: ... Place the panel in the original position Panel B To remove the panel 1 Remove panel A 2 Remove the front carrier by removing the bolts 1 Panel A 1 Carrier bolt under the fenders UB3860E0 book Page 11 Monday July 14 2014 10 34 AM ...

Page 103: ...el 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 2 Carrier bolt upper 1 Carrier bolt lower 1 Panel B 2 Quick fastener UB3860E0 book Page 12 Monday July 14 2014 10 34 AM ...

Page 104: ...r screws and then pull the panel upward to remove it To install the panel 1 Place the panel in the original position and then install the quick fastener screws Tightening torques Carrier bolt upper 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt lower 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Panel C 2 Quick fastener screw UB3860E0 book Page 13 Monday July 14 2014...

Page 105: ...ls A and C 2 Remove the quick fastener screw and bolt and then pull the panel upward to remove it TIP To ease removal of panel D shift the drive select lever into the reverse position 1 Panel D 2 Quick fastener screw 1 Bolt UB3860E0 book Page 14 Monday July 14 2014 10 34 AM ...

Page 106: ... a panel 1 Place the panel in the original position and then install the bolt and quick fastener screw 2 Install panels A and C 1 Panel E 2 Quick fastener screw 1 Bolt UB3860E0 book Page 15 Monday July 14 2014 10 34 AM ...

Page 107: ...ull the panel downward while pushing the projection To install a panel 1 Place the panel in the original position 1 Panel F 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection 1 Panel G 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection UB3860E0 book Page 16 Monday July 14 2014 10 34 AM ...

Page 108: ... H To remove the panel 1 Remove the seat See page 4 18 2 Remove the rear carrier by removing the bolts Tightening torques Panel bolt 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard nut 4 0 Nm 0 40 m kgf 2 9 ft lbf 1 Carrier bolt under the fenders UB3860E0 book Page 17 Monday July 14 2014 10 34 AM ...

Page 109: ...on the areas shown To install the panel 1 Place the panel in the original position and then install the quick fasteners 1 Rear carrier 2 Carrier bolt upper 1 Carrier bolt lower 1 Panel H 2 Quick fastener 2 1 UB3860E0 book Page 18 Monday July 14 2014 10 34 AM ...

Page 110: ...emove the quick fastener pull the radiator grill outward at the top and then pull it upward To install a radiator grill Place the radiator grill in its original position and then install the quick fastener Tightening torques Carrier bolt upper 60 Nm 6 0 m kgf 43 ft lbf Carrier bolt lower 60 Nm 6 0 m kgf 43 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Radiator grill 2 Quick fas...

Page 111: ...dition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 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 norm...

Page 112: ...ecessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification To install the spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK CPR7EA 9 1 Sp...

Page 113: ... replaced at the intervals specified in the periodic maintenance and lubrica tion chart To check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least 10 minutes until the oil set tles for an accurate reading 3 Remove the acce...

Page 114: ...the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level NOTICE Be sure the engine oil is at the correct level otherwise engine damage may result ECB00852 7 Insert the dipstick completely into the oil filler hole 8 Install the access cover by turning it clock wise 1 Engine oil dipstick 1 Maximum level mark 2 Minimum level mark UB3860E0 book Page 23 Monday...

Page 115: ...in bolt and its gasket to drain the oil from the crankcase TIP Skip steps 5 9 if the oil filter cartridge is not being replaced 5 Remove panel F See page 8 10 6 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer 7 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge 1 Engine oil drain bolt 2 Gasket 1 2 ...

Page 116: ... torque with a torque wrench 9 Install panel F 10 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the spec ified torque 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf UB3860E0 book Page 25 Monday July 14 2014 10 34 AM ...

Page 117: ...r oil leakage If oil is leaking immediately 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 the access cover by turning it clock wise EBU27307 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 repa...

Page 118: ... to raise it to the correct level 4 Check the gaskets for damage and replace them if necessary 5 Install the oil level check bolt the oil filler bolt and their gasket and then tighten the bolts to the specified torques 1 Final gear oil 2 Gasket 3 Final gear oil level check bolt 4 Correct oil level 1 2 4 3 1 Final gear oil filler bolt 2 Gasket Tightening torques Final gear oil level check bolt 10 N...

Page 119: ...in bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended final gear oil to the brim of the check hole as shown NOTICE Be sure no foreign material en ters the final gear case ECB00422 1 Final gear oil drain bolt 2 Gasket 1 2 Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil 2 Gasket 3 Final gear oil level check b...

Page 120: ... 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 2 Remove the differential gear oil filler bolt and its gasket and then check the oil level in the differential gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil ...

Page 121: ... the drain bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended differential gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material en ters the differential gear case ECB00412 Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Differential gear oil drain bolt 2 Gasket 1 2 Tightening torque ...

Page 122: ...intervals specified in the periodic maintenance and lubrication chart EBU27129 To check the coolant level 1 Place the ATV on a level surface TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser voir TIP The coolant should be between the minimum and maximum level marks Recommended differential gear oil...

Page 123: ... coolant as soon as possible otherwise the cooling system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze con tent of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECB01012 TIP The radiator fan is automatically switched on or off according to the coolant temperature in th...

Page 124: ...maining pressure to escape before completely removing the cap 1 Place the ATV on a level surface 2 Remove panel D See page 8 10 3 Remove the footboard by removing the bolts and nuts 4 Place a container under the engine and then remove the coolant drain bolt and its gasket Use a trough or a similar object as shown to prevent coolant from spilling on the engine guard 1 Footboard 2 Bolt and nut 3 Bol...

Page 125: ...Remove the coolant reservoir cap 8 Disconnect the coolant reservoir hose on the coolant reservoir side and then drain the coolant from the coolant reservoir 1 Coolant drain bolt 2 Gasket 1 Trough 1 2 1 1 Radiator cap UB3860E0 book Page 34 Monday July 14 2014 10 34 AM ...

Page 126: ... available soft water may be used for refilling Do not use hard water or salt water since they are harmful to the engine ECB00992 14 Loosen the water pump air bleed bolt with out removing it to allow all of the air to es cape from the air bleed bolt hole 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 127: ... clamp screw and then remove the V belt cooling duct 18 Loosen the cylinder head air bleed bolt with out removing it to allow all of the air to es cape from the air bleed bolt hole 1 Water pump air bleed bolt Tightening torque Water pump air bleed bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 1 V belt cooling duct 2 Clamp screw UB3860E0 book Page 36 Monday July 14 2014 10 34 AM ...

Page 128: ...ooled add sufficient coolant until it reaches the top of the radiator and then in stall the radiator cap 24 Start the engine and then check for coolant leakage TIP If any leakage is found have a Yamaha dealer check the cooling system 25 Install the V belt cooling duct and then tight en the clamp screw 26 Install the footboard by installing the bolts and nuts and then tighten them to the speci fied...

Page 129: ...els 1 Footboard nut 2 Footboard bolt A 3 Footboard bolt B 3 1 2 1 Tightening torques Footboard nut 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard bolt A 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard bolt B 7 Nm 0 7 m kgf 5 1 ft lbf 4 1 2 3 UB3860E0 book Page 38 Monday July 14 2014 10 34 AM ...

Page 130: ...sty areas TIP There are two check hoses at the bottom of the air filter case which are located behind panels D and E See page 8 10 for an explanation on removing the panels Check the hoses periodically and if dust or water collects in them empty them and clean the air filter element and air filter case 1 Place the ATV on a level surface 2 Remove panel C See page 8 10 1 Air filter case check hose 1...

Page 131: ...ove the sponge material and the air filter mesh from the air filter case 5 Clean the mesh with solvent and then wipe the solvent off 1 Air filter case cover holder 2 Air filter case cover 1 Sponge material 2 Air filter mesh UB3860E0 book Page 40 Monday July 14 2014 10 34 AM ...

Page 132: ...ge material TIP The sponge material should be wet but not drip ping 10 Install the mesh and the sponge material into the air filter case NOTICE Make sure that the air filter element is properly seated in the air filter case Never operate the en gine with the air filter element removed Doing so would allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addit...

Page 133: ...eck the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the throttle body and the rub ber joint manifold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine EBU28904 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove...

Page 134: ...e of the tailpipe housing 4 Check the gasket for damage and replace it if necessary 5 Make sure the gasket is properly positioned then insert the tailpipe into the muffler and align the bolt holes 6 Install the bolts and tighten them to the spec ified torque 1 Tailpipe bolt 1 1 1 Gasket 2 Spark arrester 3 Tailpipe Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf 3 2 1 UB3860E0 book Page ...

Page 135: ...he case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the water may affect other engine parts EBU29703 Adjusting the throttle lever free play The throttle lever free play should be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The throttle lever free play should measure 3 0 5 0...

Page 136: ...rt EBU24072 Adjusting the drive select lever safety system cable The drive select lever safety system cable stretch es with use which can result in improper function Therefore the safety system cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EBU29602 Brakes Replacement of brake components requires pro fessional kn...

Page 137: ...tor groove which allows you to check the brake pad wear without having to disassemble the brake If a brake pad has worn to the point that the wear in dicator groove has almost disappeared have a Yamaha dealer replace the brake pads as a set TIP The wheels need to be removed to check the brake pads See page 8 64 Front brake Rear brake 1 Wear indicator groove 1 Wear indicator groove UB3860E0 book Pa...

Page 138: ...rake Rear brake WARNING EWB02721 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may allow air to enter the brake system reducing braking perfor mance Clean the filler cap before removing Use only DOT 4 brake fluid from a sealed contain er 1 Minimum level mark 2WD 4WD 1 1 Minimum level mark Specified brake fluid DOT 4 UB3860E0 book Page...

Page 139: ...ads for wear and the brake system for leakage If the brake fluid level goes down sud denly have a Yamaha dealer check the cause be fore further riding EBU24293 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrication chart In addition have the oil seals of the master cylinders and calipers as well as the brake hoses...

Page 140: ...ys perform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting the brake pedal free play check the rear brake pads for wear The brake pedal free play should measure 1 0 6 0 mm 0 04 0 24 in as shown If the free play is in correct adjust it as follows 1 No brake lever free play 1 No brake lever free play UB3860E0 book Page 49 Monday July 14 2014 10 3...

Page 141: ...ncrease the free play and in direction b to decrease it 4 Tighten the locknut 5 After adjusting there should be slight play at the brake pedal cable joint as shown If there is no play repeat steps 2 to 4 1 Brake pedal free play 1 Locknut 2 Brake pedal free play adjusting nut UB3860E0 book Page 50 Monday July 14 2014 10 34 AM ...

Page 142: ...nd brake pedal do not move EBU24231 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them replaced by a Yamaha dealer 1 Brake pedal cable joint 2 Slight play 0 1 0 5 mm 0 004 0 02 in 1 2 1 Front axle boot each side 1 1 UB3860E0 book Page 51 Monday Ju...

Page 143: ... operation of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an accident or collision EBU24913 Checking and lubricating the front and rear brake levers The operation of the front and rear brake leve...

Page 144: ...dal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel G See page 8 10 Recommended lubricant Lithium soap based grease UB3860E0 book Page 53 Monday July 14 2014 10 34 AM ...

Page 145: ...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 EBU25053 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with a grea...

Page 146: ...anger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention...

Page 147: ...tery 1 Remove panel A See page 8 10 2 Remove the front carrier by removing the bolts 1 Carrier bolt under the fenders 1 Front carrier 2 Carrier bolt upper 1 Carrier bolt lower UB3860E0 book Page 56 Monday July 14 2014 10 34 AM ...

Page 148: ...ith optional elec trical accessories NOTICE ECB00932 To charge a VRLA Valve Regulated Lead Acid battery a special constant voltage battery charger is required Using a conventional bat tery charger will damage the battery To store the battery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for...

Page 149: ...ust be connected before the negative lead ECB01111 3 Install the battery holding plate by installing the nuts 4 Install the front carrier by installing the bolts and tightening them to the specified torques 5 Install the panel 1 Positive battery lead red 2 Negative battery lead black 1 2 Tightening torques Carrier bolt upper 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt lower 34 Nm 3 4 m kgf 25 ft lbf Ca...

Page 150: ...e it as follows 1 Turn the key to off and turn off all elec trical circuits 1 Fuse box 2 Main fuse 3 EPS fuse 4 Fuel injection system spare fuse 5 Fuel injection system fuse 1 Auxiliary DC jack fuse 2 Four wheel drive motor fuse 3 Ignition fuse 4 Radiator fan motor fuse 5 Signaling system fuse 6 Headlight fuse 7 Spare fuse UB3860E0 book Page 59 Monday July 14 2014 10 34 AM ...

Page 151: ...can cause damage to the electrical system which could lead to a fire EWB02173 3 Turn the key to on and turn on the elec trical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system Specified fuses Main fuse 40 0 A Headlight fuse 10 0 A Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A Signaling system fuse 5 0 A Auxili...

Page 152: ...e it as follows 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the headlight bulb cover 3 Disconnect the headlight coupler 1 Cover at the rear of the headlight 1 Headlight bulb cover 1 Headlight coupler UB3860E0 book Page 61 Monday July 14 2014 10 34 AM ...

Page 153: ...nd fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner ECB00652 6 Connect the headlight coupler 7 Install the headlight bulb cover NOTICE Make sure the headlight bulb cover is se curely fitted and seated properly ECB01081 8 Install the cover at the rear of the headlight 9 Adjust the headlight beam if necessary EBU25552 Adjusting a headlight beam NOTICE ECB00691 It is...

Page 154: ... the tail brake light bulb burns out replace it as follows 1 Remove panel H See page 8 10 2 Remove the tail brake light bulb holder to gether with the bulb by turning it counter clockwise 3 Remove the burnt out bulb by pushing it in and turning it counterclockwise 1 Headlight beam adjusting screw 1 Tail brake light bulb holder 1 Tail brake light bulb UB3860E0 book Page 63 Monday July 14 2014 10 34...

Page 155: ...evate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU25702 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP The arrow mark on the tire must point to ward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side towards the...

Page 156: ... to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02281 Do not smoke when checking the fuel system Fuel can ignite or explode causing s...

Page 157: ...e the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Check the compression Dry Wet Operate the electric starter Have a Yamaha dealer check the ATV The engine does not start Check the ignition Operate the electric starter 2 Battery The engine turns over qui...

Page 158: ...r can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If the engine overheats ...

Page 159: ...ion dry out the linings EWB02312 NOTICE Excessive wa ter pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure de tergent applications such as those avail able in coin operated car washers ECB00712 4 Once most of the dirt has been hosed off wash all surfaces with wa...

Page 160: ...the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil e Remove the spark plug cap ...

Page 161: ... it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more infor mation on storing the battery see page 8 55 TIP Make any necessary repairs before storing the ATV UB3860E0 book Page 3 Monday July 14 2014 10 34 AM ...

Page 162: ...ion on seat EN1032 ISO5008 YFM700FWAD Will not exceed 0 5 m s YFM700PF Will not exceed 0 5 m s EUR FRA GBR YFM700PHF Will not exceed 0 5 m s YFM700PSF Will not exceed 0 5 m s EUR FRA GBR Vibration on handle EN1032 ISO5008 YFM700FWAD Will not exceed 2 5 m s YFM700PF Will not exceed 2 5 m s EUR FRA GBR YFM700PHF Will not exceed 2 5 m s YFM700PSF Will not exceed 2 5 m s EUR FRA GBR Engine Engine type...

Page 163: ...lant quantity Coolant reservoir up to the maximum level mark 0 24 L 0 25 US qt 0 21 Imp qt Radiator including all routes 1 99 L 2 10 US qt 1 75 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular 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 Fuel injection Throttle body ID mark 2BG1 00 Spark p...

Page 164: ... MAXXIS MU19A EUR FRA GBR YFM700PHF MAXXIS MU19A YFM700PLF CHENG SHIN C828 YFM700PSF CHENG SHIN C828 AUS NZL YFM700PSF MAXXIS MU19A EUR FRA GBR Rear tire Type Tubeless Size AT25 x 10 12 Manufacturer model YFM700FWAD MAXXIS MU20A YFM700PF CHENG SHIN C828 AUS NZL YFM700PF MAXXIS MU20A EUR FRA GBR YFM700PHF MAXXIS MU20A YFM700PLF CHENG SHIN C828 YFM700PSF CHENG SHIN C828 AUS NZL YFM700PSF MAXXIS MU20...

Page 165: ...ight foot operation Specified brake fluid DOT 4 Front suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 193 mm 7 6 in Rear suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 232 mm 9 1 in Electrical system Ignition system TCI Charging system AC magneto Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Head...

Page 166: ...se 5 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Four wheel drive motor fuse 10 0 A Radiator fan motor fuse 20 0 A EBU30402 For Europe only The figures quoted are emission levels and are not necessarily safe working levels Whilst there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required Facto...

Page 167: ...10 6 10 sure level can vary from country This information however will enable the user of the machine to make a better evaluation of the hazard and risk UB3860E0 book Page 6 Monday July 14 2014 10 34 AM ...

Page 168: ...L LABEL INFORMATION EBU26031 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to iden tify your ATV EBU26051 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 ed when ordering spare parts from a Yam...

Page 169: ...11 2 11 1 Model label UB3860E0 book Page 2 Monday July 14 2014 10 34 AM ...

Page 170: ...al gear oil 5 3 8 29 Drive select lever 4 15 Drive select lever and driving in reverse 6 2 Drive select lever safety system cable adjusting 8 45 E Engine break in 6 4 Engine oil 5 3 Engine oil and oil filter cartridge 8 22 Engine stop switch 4 8 Engine trouble warning light 4 3 EPS warning light 4 3 F Final gear oil 5 3 8 26 Four wheel drive differential gear lock indicator 4 4 Front and rear brak...

Page 171: ...ht 4 2 Riding your ATV 7 1 S Safety information 2 1 Seat 4 18 Shock absorber assemblies adjusting the front and rear 4 21 Spark arrester cleaning 8 42 Spark plug checking 8 20 Specifications 10 1 Speed limiter 4 13 Stabilizer bushes checking 8 54 Starting the engine 6 1 Start switch 4 8 Steering shaft lubricating 8 55 Storage 9 2 Storage compartments 4 18 T Tail brake light bulb replacing 8 63 Thr...

Page 172: ... APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS 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 LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND...

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