Yamaha Grizzly 300 Owner's Manual
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Yamaha Grizzly 300 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM30GD
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-26-13
1SC-F8199-11

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Summary of Contents for Yamaha Grizzly 300

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM30GD WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-26-13 1SC-F8199-11...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 Please check your local riding laws and regulations before operating this ATV. YFM30GD OWNER’S MANUAL ©2012 by Yamaha Motor Corporation,U.S.A. 1st edition, May 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation,U.S.A.

  • Page 8: Table Of Contents

    Brake pedal and rear brake lever ....4-5 WARNING Parking brake lever ........4-6 Indicates a potential hazard that could result in Drive select lever ........4-7 serious injury or death. Fuel tank cap ..........4-8 Fuel .............4-8 TABLE OF CONTENTS Fuel cock ..........4-10 Starter (choke) ..........4-11 LOCATION OF THE WARNING AND...
  • Page 9 OPERATION ..........6-1 PERIODIC MAINTENANCE AND Starting a cold engine ........ 6-1 ADJUSTMENT..........8-1 Starting a warm engine ......6-3 Owner’s manual and tool kit .......8-2 Operating the drive select lever and Periodic maintenance chart for the driving in reverse ........6-3 emission control system ......8-3 Engine break-in ..........
  • Page 10 Noise regulation ........11-3 Checking and lubricating the cables ..8-38 Maintenance record ........ 11-4 Checking and lubricating the front and YAMAHA MOTOR CORPORATION, rear brake levers ........8-38 U.S.A. ATV LIMITED WARRANTY ..11-5 Checking and lubricating the brake YAMAHA EXTENDED SERVICE pedal ............

  • Page 11: Location Of The Warning And Specification Labels

    Read and understand all of the labels 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 replace- ment label from your Yamaha dealer.
  • Page 13 2226 N (227 kgf) 500 lbf 147 N ( 15 kgf) 33 lbf...

  • Page 14: Safety Information

    SAFETY INFORMATION Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 15 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 16 steady speed when climbing a hill. If you stall or Always be sure there are no obstacles or people roll backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 17 In the event of a breakdown: safer staying next to your vehicle; it may shield you from oncoming riders. Depending on your 1. If your vehicle will not restart or is not in safe injuries and position in the trail; you must make operating condition, turn off the main switch a judgement call as to whether should move to and engine stop switch.
  • Page 18 This im- While you may find aftermarket products similar in proper position limits the freedom of movement design and quality to genuine Yamaha accessories, of the operator and may limit control ability, recognize that some aftermarket accessories or therefore, such accessories are not recommended.
  • Page 19 WARNING openings such as windows and doors. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, WARNING a deadly gas. Breathing carbon monoxide can When transporting the ATV in another vehicle, cause headaches, dizziness, drowsiness, nau- be sure it is kept upright and that the fuel cock sea, confusion, and eventually death.

  • Page 20: Description

    DESCRIPTION Left view Right view 1. Fuel cock 1. Battery and fuses 2. Air filter case 2. Throttle stop screw 3. Rear storage compartment and tool kit 3. Radiator cap 4. Spark arrester 4. Coolant reservoir 5. Tail/brake light 5. Engine oil filler cap 6.

  • Page 21: Controls And Instruments

    Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Indicator lights and warning light 4. Front brake lever 5. Throttle lever 6. Drive select lever 7.

  • Page 22: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS WARNING Indicates a potential hazard that could result in serious injury or death. Main 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.

  • Page 23: Indicator Lights And Warning Light

    If the warning light does not come on initially when the key is turned to “ ” (on), or if the warning light remains on, have a Yamaha dealer check the elec- trical circuit. 1. Coolant temperature warning light “...

  • Page 24: Handlebar Switches

    Start switch “ ” Handlebar switches Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. Light switch “ /OFF” Set this switch to “ ” to turn on the low beams and the taillight.

  • Page 25: Throttle Lever

    Throttle lever Speed limiter Your ATV is equipped with an adjustable speed Once the engine is running, pushing the throttle limiter. The speed limiter keeps the throttle from lever will increase the engine speed. fully opening, even when the throttle lever is Regulate the speed of the ATV by varying the throttle pushed to the maximum.

  • Page 26: Front Brake Lever

    Front brake lever (See page 8-29.) WARNING! Improper ad- justment of the speed limiter and throttle The front brake lever is located on the right handle- could cause throttle cable damage or im- bar. To apply the front brake, pull the brake lever proper throttle operation.

  • Page 27: Parking Brake Lever

    Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a). To release the parking brake, move the parking brake lever in direction (b). 1.

  • Page 28: Drive Select Lever

    Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, and reverse positions. See the“ Operating the drive select lever and driving in reverse ”section on page 6-3 for the drive select lever operation. 1.

  • Page 29: Fuel Tank Cap

    1. Before refueling, turn off the engine and be Fuel tank cap sure that no one is sitting on the vehicle. Nev- Remove the fuel tank cap by turning it counter- er refuel while smoking, or while in the vicinity clockwise.
  • Page 30 Fuel reserve amount: 3.0 L (0.79 US gal, 0.66 Imp.gal) Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane 3. Wipe up any spilled fuel immediately.

  • Page 31: Fuel Cock

    Fuel cock The fuel cock supplies fuel from the tank to the car- buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel flows to the carburetor.

  • Page 32: Starter (Choke)

    Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mix- ture, which is supplied by the starter (choke). Move the starter (choke) in direction (a) to turn on the starter (choke). Move the starter (choke) in direction (b) to turn off the starter (choke).

  • Page 33: Seat

    To install the seat Seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the To remove the seat rear. Make sure that the seat is securely fitted. Pull the seat lock lever upward and pull up the seat at the rear.

  • Page 34: Front Carrier

    2. Position indicator WARNING Always adjust the shock absorber assemblies A special wrench can be obtained at a Yamaha on the left and right side to the same setting. dealer to make this adjustment. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident.
  • Page 35 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): WARNING Indicates a potential hazard that could result in serious injury or death. 4-14...

  • Page 37: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points: •...
  • Page 38 • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-31, 8-32, 8-33, 8-34 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 39: Fuel

    Brake levers and brake pedal Check that there is no free play in the front brake Transfer gear oil lever. If there is free play, have a Yamaha dealer check the brake system. Make sure that the Transfer gear oil is at the spe- Check for correct free play in the rear brake lever cified level.

  • Page 40: Throttle Lever

    If there is any leakage, the brake Tire pressure system should be checked by a Yamaha dealer. Use the low-pressure tire gauge to check and ad- just tire pressures when the tires are cold. Tire Brake operation pressures must be equal on both sides.
  • Page 41 Recommended tire pressure: Front 30.0 kPa (0.300 kgf/cm², 4.4 psi) Rear 25.0 kPa (0.250 kgf/cm², 3.6 psi) Minimum tire pressure: Front 27.0 kPa (0.270 kgf/cm², 4.0 psi) Rear 22.0 kPa (0.220 kgf/cm², 3.2 psi) 1. Low-pressure tire gauge The low-pressure tire gauge is included as stan- dard equipment.

  • Page 42: Chassis Fasteners

    Type: dent. Tubeless After extensive tests, only the tires listed below have been approved for this model by Yamaha Aftermarket tires and rims Motor Co., Ltd. The tires and rims that came with your ATV were designed to match the performance capabilities...

  • Page 43: Operation

    The corresponding indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. Read the Owner’s Manual carefully before riding the ATV. If there is a control or function you do not understand, ask your Yamaha dealer.
  • Page 44 Position (3): Cold engine start with ambient temperature If the engine fails to start, release the start switch, above 25 °C (80 °F). then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy.

  • Page 45: Starting A Warm Engine

    Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. Operating the drive select lever and driving in reverse NOTICE 1.

  • Page 46: Engine Break-In

    When in reverse, the reverse indicator light should come on. If the indicator light does not go slowly. come on, have a Yamaha dealer check the elec- 1. Bring the ATV to a complete stop. trical circuit. 2. Apply the brake pedal. The drive select lever...

  • Page 47: Parking

    320 km (200 mi) or 20 hours and beyond The ATV can now be operated normally. NOTICE If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. 1. Locked position...

  • Page 48: Parking On A Slope

    ATV. Many companies with no con- nection to Yamaha manufacture parts and acces- sories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies pro- duce. Therefore, Yamaha can neither endorse nor...
  • Page 49 Yamaha or modifications not specifically recom- bulky object attached to the handlebars which mended by Yamaha, even if sold and installed by could make steering difficult, an accessory that a Yamaha dealer. limits your ability to move around on the seat, or one that limits your view.
  • Page 50 Never exceed the weight limits shown. An over- Load cargo on the carriers as close to the center loaded ATV can be unstable. of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, MAXIMUM LOADING LIMIT and center it.

  • Page 51: Riding Your Atv

    RIDING YOUR ATV...

  • Page 52: Getting To Know Your Atv

    ATV to achieve the skill necessary to enjoy Yamaha. They should then regularly practice the riding safely. Before you begin to ride, be sure you skills learned in the course and the operating te- have read this Owner’s Manual completely and un-...
  • Page 53 Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
  • Page 54 Apparel Always wear the following to reduce risk of injury in an accident: Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 55 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots Perform the pre-operation checks listed on page 5. Helmet 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 56 Do not exceed the maximum loading limits opening, even when the throttle lever is pushed to for the vehicle (see box in this section or ve- the maximum. Turning in the adjusting screw limits the maximum engine power available and de- hicle labeling).
  • Page 57 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of rider, cargo, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 155.0 kg (342 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
  • Page 58 ATV should be during operation or after leaving the ATV, do not let genuine Yamaha or equivalent components de- brush, grass and other materials collect under the signed for use on this ATV and should be installed vehicle, near the muffler or exhaust pipe, or next to and used according to instructions.

  • Page 59: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE To prevent burns, avoid touching the exhaust sys- tem. Park the ATV in a place where pedestrians or This ATV is designed for off-road use only. children are not likely to touch it. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 60 ful when operating on unfamiliar terrain. Al- other vehicles. In many states it is illegal to operate ways be alert to changing terrain conditions ATVs on public streets, roads and highways. when operating the ATV. WARNING! Never operate this ATV on any public street, road or highway, even a dirt or gravel one.
  • Page 61 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 62: Turning Your Atv

    Select a large, flat, unpaved area to become famil- NOTICE iar with your ATV. Make sure that this area is free Do not shift from low-range to high-range or of obstacles and other riders. You should practice vice versa without coming to a complete stop. control of the throttle, brakes, shifting procedures, Damage to the engine or drive train may occur.

  • Page 63: Climbing Uphill

    As you approach a curve, slow down and begin to may continue to go straight. If the ATV doesn’t turn the handlebars in the desired direction. As you turn, come to a stop and then practice the proce- do so, put your weight on the footboard to the out- dure again.
  • Page 64 Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
  • Page 65 Do not attempt to climb hills until you have mas- If you are climbing a hill and you find that you have not properly judged your ability to make it to the tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any top, you should turn the ATV around while you still hill.

  • Page 66: Riding Downhill

    Always check the terrain carefully before remount, following the procedure described in the Owner’s Manual. WARNING! Stalling, rolling you start down any hill. backwards or improperly dismounting while Never operate the ATV on hills too steep for climbing a hill could result in ATV overturning. the ATV or for your abilities.

  • Page 67: Crossing A Slope

    Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. Gradually apply only the rear brake. Whenever possible, ride your ATV straight down- hill.

  • Page 68: Crossing Through Shallow Water

    Shift your weight to the uphill side of the ATV. 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.
  • Page 69 The ATV can be used to cross slow moving, shal- ability. WARNING! Wet brakes may have re- low water of up to a maximum of 20 cm (7.9 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.

  • Page 70: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN Wash the ATV in fresh water if it has been operat- ed in salt water or muddy conditions. WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees.
  • Page 71 Learn to safely control skidding or sliding by If the rear wheels of your ATV start to slide side- practicing at low speeds and on level, ways, control can usually be regained (if there is smooth terrain. room to do so) by steering in the direction of the On extremely slippery surfaces, such as ice, slide.

  • Page 72: What To Do If

    WHAT TO DO IF... THE REAR BRAKE – the ATV may tip over on This section is designed to be a reference guide top of you. Dismount the ATV on the uphill side. only. Be sure to read each section on riding tech- (See page 7-13.) niques completely.

  • Page 73: Periodic Maintenance And Adjustment

    If you are not fa- ing them. miliar with vehicle service, have a Yamaha dealer perform the service. The intervals given in the periodic maintenance and lubrication chart should be considered as a general guide under normal riding conditions.

  • Page 74: Owner's Manual And Tool Kit

    Put the owner’s tool kit and low-pres- sure tire gauge under the seat. 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.

  • Page 75: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 76 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 77: General Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • •...
  • Page 79 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ 15 * Engine mount necessary. •...
  • Page 80 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. Throttle lever hous- • Check throttle lever free play and adjust if neces- √...

  • Page 81: Checking The Spark Plug

    WARNING Indicates a potential hazard that could result in serious injury or death. Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart.
  • Page 82 4. Remove the spark plug as shown, with the attempt to diagnose such problems yourself. In- spark plug wrench included in the owner’s tool stead, have a Yamaha dealer check the ATV. kit. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.
  • Page 83 To install the spark plug 4. Place the left side cover in its original position, 1. Clean the surface of the spark plug gasket push forward on the areas shown, and then and its mating surface, and then wipe off any push inward as shown.

  • Page 84: Engine Oil

    Engine oil If the engine was started before checking the oil The engine oil level should be checked before level, be sure to warm up the engine sufficiently, each ride. In addition, the oil must be changed at and then wait at least ten minutes until the oil set- the intervals specified in the periodic maintenance tles for an accurate reading.
  • Page 85 To change the engine oil 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4.
  • Page 86 6. Install the engine oil drain bolt, and then tight- 9. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if en it to the specified torque. necessary. Tightening torque: 10. Place the engine oil cap cover in its original Engine oil drain bolt: position, and push inward to secure it.

  • Page 87: Transfer Gear Oil

    The transfer gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the transfer gear oil must be changed at the intervals specified in the periodic mainten- ance and lubrication chart.
  • Page 88 6. Remove the transfer gear filling bolt and 7. Install the drain bolt, and then tighten it to the the drain bolt to drain the oil from the transfer specified torque. gear oil case. Tightening torque: Transfer gear filling bolt: 15 Nm (1.5 m·kgf, 10.8 ft ·lbf) Transfer gear oil drain bolt: 40 Nm (4.0 m·kgf, 28.9 ft·lbf)

  • Page 89: Final Gear Oil

    Place the right side cover in its original po- age before each ride. If any leakage is found, have sition, push forward on the areas shown, and a Yamaha dealer check and repair the ATV. In then push inward as shown. addition, the final...

  • Page 90: Coolant

    4. Install the drain bolt, and then tighten it to the Coolant specified torque. The coolant level should be checked before each ride. In addition, the coolant must be changed at Tightening torque: the intervals specified in the periodic maintenance Final gear oil drain bolt:...
  • Page 91 If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced.
  • Page 92 when opening. Allow any remaining pressure 3. Remove the front carrier by removing the bolts. to escape before completely removing the cap. 1. Place the ATV on a level surface. 2. Place a container under the engine, and then remove the coolant drain bolt. 1.
  • Page 93 4. Remove the front panel by removing the quick 5. Remove the radiator cap. fastener screws, and then pull the front panel upward to remove it. 1. Radiator cap 6. Remove the coolant reservoir cap. 1. Front panel 2. Quick fastener screw 8-21...
  • Page 94 7. Disconnect the hose on the coolant reservoir 10. Connect the coolant reservoir hose. side, and then drain the coolant from the cool- 11. Pour the recommended coolant into the reser- ant reservoir. voir to the maximum level mark, and then install the reservoir cap.

  • Page 95: Cleaning The Air Filter Element

    There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty If any leakage is found, have a Yamaha dealer the hose and clean the air filter element and air fil- check the cooling system.
  • Page 96 1. Place the ATV on a level surface. 4. Remove the bolts and pull the air filter element 2. Remove the seat. (See page 4-12.) out of the air filter case. 3. Remove the air filter case cover by unhooking the air filter case cover holders.
  • Page 97 3. Air filter element lock plate damaged. 4. Bolt 9. Apply Yamaha foam air filter oil or other qual- 6. Wash the sponge material gently but thor- ity foam air filter oil to the sponge material. oughly in solvent. WARNING! Always use...

  • Page 98: Cleaning The Spark Arrester

    11. Insert the air filter element into the air filter Cleaning the spark arrester case and install the bolts, and then install the Be sure the exhaust pipe and muffler are cool be- air filter case cover by hooking the holders onto fore cleaning the spark arrester.

  • Page 99: V-Belt Cooling Duct Check Hose

    3. Tap the tailpipe lightly, and then use a wire WARNING brush to remove any carbon deposits from the Do not start the engine when cleaning the spark arrester portion of the tailpipe and inside spark arrester, otherwise it could cause injury of the tailpipe housing.

  • Page 100: Adjusting The Carburetor

    1. Remove the seat. (See page 4-12.) most carburetor adjustments should be left to a 2. Remove the right side cover. (See page 8-15.) Yamaha dealer, who has the necessary profes- 3. Start the engine and warm it up. sional knowledge and experience. The adjustment...

  • Page 101: Adjusting The Throttle Lever Free Play

    3. To increase the throttle leve free play, turn If the specified idling speed cannot be obtained as the throttle leve free play adjusting bolt in di- described above, have a Yamaha dealer make the rection (a). To decrease the throttle leve free adjustment.

  • Page 102: Valve Clearance

    The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.

  • Page 103: Checking The Front Brake Pads And Rear Brake Pads

    1.5 mm aged or if the lining thickness is less than 1.5 mm (0.06 in), have a Yamaha dealer replace the brake (0.06 in), have a Yamaha dealer replace the brake pads as a set.

  • Page 104: Checking The Brake Fluid Level

    Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid level with the top of the reservoir level.Replenish the brake fluid if necessary. 1. Minimum level mark (for the rear brake) Specified brake fluid: DOT 4 1.

  • Page 105: Changing The Brake Fluid

    Changing the brake fluid WARNING Have a Yamaha dealer change the brake fluid at Improper maintenance can result in loss of the intervals specified in the TIP after the periodic braking ability. Observe these precautions: maintenance and lubrication chart. In addition,...

  • Page 106: Checking The Front Brake Lever Free Play

    (zero in) as shown. If the free tenance and lubrication chart. play is incorrect, have a Yamaha dealer check the brake system. Adjusting the brake lever free play The brake lever free play should measure 4.0–...

  • Page 107: Adjusting The Parking Brake Free Play

    (a) to increase the free play, and If the brake pedal position is incorrect, have a in direction (b) to decrease it. Yamaha dealer adjust it. 1. Locknut 2. Brake lever free play adjusting bolt 1. Distance between brake pedal and footboard Adjusting the parking brake free play 3.
  • Page 108 3. Locknut If the cable length cannot be adjusted to specifica- 1. Release the parking brake by moving the tion, consult a Yamaha dealer. parking brake lever to the left. 2. Fully loosen the locknut and the adjusting bolt 5. Tighten the locknut on the brake cable.

  • Page 109: Rear Axle Boot

    The brake light switch for the brake pedal can be adjusted as follows, but the front brake light switch Rear axle boot should be adjusted by a Yamaha dealer. The axle boot must be checked for damage at the 1. Remove the right footboard. (See page 8-15.) intervals specified in the periodic maintenance and lubrication chart.

  • Page 110: Checking And Lubricating The Cables

    2. Turn the brake light switch adjusting nut while smoothly, have a Yamaha dealer check or replace it. holding the brake light switch in place. To make the brake light come on earlier, turn the Recommended lubricant: adjusting nut in direction (a). To make the...

  • Page 111: Checking And Lubricating The Brake Pedal

    Checking and lubricating the brake Recommended lubricants: Front brake lever: pedal Silicone grease The operation of the brake pedal should be Rear brake lever: checked before each ride, and the pedal pivot Lithium-soap-based grease should be lubricated if necessary. Front brake lever To access the brake pedal pivot, remove the right footboard.

  • Page 112: Checking The Wheel Hub Bearings

    Checking the wheel hub bearings Lubricating the steering shaft The front and rear wheel hub bearings must be The steering shaft must be lubricated by a Yamaha checked at the intervals specified in the periodic dealer at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 113: Battery

    Batteries produce explosive gases. Keep Battery sparks, flame, cigarettes or other sources of ig- This model is equipped with a VRLA (Valve Regu- nition away. Ventilate when charging or using lated Lead Acid) battery. There is no need to check in an enclosed space.
  • Page 114 Always keep the battery charged. Storing a dis- To charge the battery charged battery can cause permanent battery Have a Yamaha dealer charge the battery as soon damage. as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.

  • Page 115: Replacing A Fuse

    To install the battery 4. Install the seat. (See page 4-12.) Be sure the battery is fully charged. Replacing a fuse 1. Place the battery in its compartment. The fuse boxes are located under the seat. (See 2. Connect the positive battery lead first, then page 4-12.) connect the negative battery lead by installing their bolt.
  • Page 116 An 4. If the fuse immediately blows again, have a improper fuse or a substitute object can Yamaha dealer check the electrical system. cause damage to the electrical system, which could lead to a fire.

  • Page 117: Replacing A Headlight Bulb

    Replacing a headlight 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. 1. Headlight bulb holder cover 3. Disconnect the headlight coupler. 1. Cover at the rear of the headlight 2.
  • Page 118 4. Push the headlight bulb hold cables inward, finger prints on the headlight bulb using pull it outward as shown. a cloth moistened with alcohol or thinner. 1. Do not touch the glass part of the bulb. 1. Headlight bulb holder 2.

  • Page 119: Adjusting A Headlight Beam

    Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as NOTICE follows. It is advisable to have a Yamaha dealer make 1. Remove the tail/brake light assembly by re- this adjustment. moving the nuts together with the washers.
  • Page 120 2. Remove the tail/brake light cover by removing 3. Remove the burnt-out bulb by pushing it in the bolts. and turning it counterclockwise. 1. Tail/brake light cover 1. Tail/brake light bulb holder 2. Bolts 2. Tail/brake light bulb 4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops.

  • Page 121: Removing A Wheel

    Installing a wheel Removing a wheel 1. Place the ATV on a level surface. 1. Place the ATV on a level surface. 2. Install the wheel and the nuts. 2. Loosen the wheel nuts. The arrow mark on the tire must point toward the rotating direction of the wheel.

  • Page 122: Troubleshooting

    The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- 1. Tapered nut rience, and know-how to service the ATV properly.

  • Page 123: Troubleshooting Charts

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.
  • Page 124 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.

  • Page 125: Cleaning And Storage

    CLEANING AND STORAGE wheel bearings, brakes, transmission seals Cleaning and electrical devices. Many expensive Frequent, thorough cleaning of your ATV will not repair bills have resulted from improper only enhance its appearance but will improve its high-pressure detergent applications such general performance and extend the useful life of as those available in coin-operated car many components.

  • Page 126: Storage

    Storage Specified amount: 7.5 ml of stabilizer to each liter of fuel (or 1 oz Short-term of stabilizer to each gallon of fuel) Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous 5.
  • Page 127 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.

  • Page 128: Specifications

    SPECIFICATIONS Dimensions: Bore × stroke: 75.0 × 65.0 mm (29.5 × 2.56 in) Overall length: Compression ratio: 1895 mm (74.6 in) 8.6 : 1 Overall width: Starting system: 1069 mm (42.1 in) Electric starter Overall height: Lubrication system: 1124 mm (44.3 in) Wet sump Seat height: 794 mm (31.3 in)
  • Page 129 Engine oil quantity: Fuel: Recommended fuel: Periodic oil change: Unleaded gasoline only 1.20 L (1.27 US qt, 1.06 Imp.qt) Fuel tank capacity: 10.7 L (2.83 US gal, 2.35 Imp.gal) Transfer gear oil: Fuel reserve amount: Type: 3.0 L (0.79 US gal, 0.66 Imp.gal) SAE 90 API GL-5 Hypoid gear oil Quantity: Carburetor:...
  • Page 130 Transmission: Manufacturer/model: MAXXIS/M919 Primary reduction system: Speed rating: V-belt 100 km/h (62 mile/h) Secondary reduction system: Rear tire: Shaft drive Type: Transmission type: Tubeless V-belt automatic Size: Operation: AT22 x 10-9 Right hand operation Manufacturer/model: Reverse gear: MAXXIS/M920 47/17 × 31/26 × 32/18 × 19/17 (6.54) Speed rating: Low range: 100 km/h...
  • Page 131 Front wheel: Front suspension: Wheel type: Type: Panel wheel Double wishbone Rim size: Spring/shock absorber type: 10 x 5.5AT Coil spring/oil damper Wheel travel: Rear wheel: 151 mm (5.9 in) Wheel type: Rear suspension: Panel wheel Type: Rim size: Swingarm 9 x 8AT Spring/shock absorber type: Coil spring/oil damper...
  • Page 132 Bulb voltage, wattage × quantity: Headlight: 12 V, 35/35 W × 2 Tail/brake light: 12 V, 5.0/21.0 W × 1 Neutral indicator light: 12 V, 1.7 W × 1 Reverse indicator light: 12 V, 1.7 W × 1 Coolant temperature warning light: 12 V, 1.7 W ×...

  • Page 133: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 134 Model label ment Canada. 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 Yamaha deal- 11-2...

  • Page 135: Noise Regulation

    Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 136: Maintenance Record

    Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 137: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 138 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 139: Yamaha Extended Service (Y.e.s.)

    Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn ’t limited to much more valuable! “moving par ts”...
  • Page 140 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 Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 141 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts - Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect. Why settle for aftermarket parts that may not provide full confidence and...
  • Page 142 INDEX Chassis fasteners ............5-6 Accessories and loading ..........Cleaning ................. Air filter element, cleaning ........... 8-23 Coolant ..............5-3, 8-18 Axle boot ............... 8-37 Coolant temperature warning light ........Battery ................8-41 Drive select lever ............Brake fluid level, checking ..........8-32 Drive select lever and driving in reverse ......
  • Page 143 Handlebar switches ............Parking ................Headlight beam, adjusting ........... 8-47 Parking brake free play, adjusting ....... 8-35 Headlight bulb, replacing ..........8-45 Parking brake lever ............Horn switch ..............Parking on a slope ............Part locations ..............Pre-operation checks............Identification numbers ........... 11-1 Indicator lights and warning light ........
  • Page 144 Tail/brake light bulb, replacing ........8-47 Throttle lever free play, adjusting ........ 8-29 Throttle lever ............4-4, 5-4 Tires ................Transfer gear oil ............ 5-3, 8-15 Troubleshooting ............8-50 Troubleshooting charts ..........8-51 Valve clearance ............8-30 V-belt cooling duct check hose ........8-27 Vehicle identification number ........

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