Page 1 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. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM45FGA YFM450FAA 1CU-F8199-60...
Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2010.06-0.4×1 CR (E,F,S)
Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45FGA YFM450FAA 1CU-F8199-60-E0...
Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM450FWA (YFM45FG) (5Y4AJ14W0A0516867–)
Page 5 Congratulations on your purchase of the Yamaha YFM45FGA/YFM450FAA. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing ma- chines. 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 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 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. EBU17410 YFM45FGA/YFM450FAA OWNER’S MANUAL ©2010 by Yamaha Motor Co., Ltd. 1st edition, May 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
Page 8: Table Of Contents
EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel cock ..........4-15 SPECIFICATION LABELS ......1-1 Starter (choke) ..........4-17 Seat ............4-17 SAFETY INFORMATION ......2-1 Storage compartments ......4-18 Front carrier ..........4-21 DESCRIPTION ..........3-1 Rear carrier ..........4-21 Left view ............3-1 Adjusting the front and rear shock Right view............
Page 9 Starting a warm engine ......6-3 Periodic maintenance chart for Operating the drive select lever and the emission control system .....8-3 driving in reverse ........6-3 General maintenance and lubrication Engine break-in .......... 6-5 chart ............8-5 Parking ............6-5 Removing and installing panels ....8-10 Parking on a slope ........
Page 10 Adjusting the rear brake lever and brake CLEANING AND STORAGE ......9-1 pedal free play, and the brake Cleaning ............9-1 pedal height ..........8-41 Storage ............9-2 Axle boots ..........8-45 Brake light switches ......... 8-46 SPECIFICATIONS ........10-1 Checking and lubricating the cables ..8-47 Checking and lubricating the front and CONSUMER INFORMATION.......11-1 rear brake levers ........
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. For Europe 9 10...
Page 12 < 40 kg ( 88 lbs) 37S-F817R-00 1P0-F816P-20 < 80 kg ( 176 lbs) 37S-F817R-10 25.0 kPa 25.0 kPa 0.25 kgf/cm² 0.25 kgf/cm² < 5880 N 3.6 psi 3.6 psi < 600 kgf < 1322 lbf 5FU-F816M-M0 < 147 N <...
Page 13 1P0-F816L-20 1P0-F816R-00...
Page 14 < 0.5 kg ( 1 lb ) 37S-F816N-00 37S-F816S-00 YFM450FWA 2010 19.4 kW YAMAHA MOTOR CO., LTD. 275 kg 2500 SHINGAI, IWATA, JAPAN 1CU-F155A-00...
Page 15 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
Page 16 NEVER use with drugs or alcohol. Adjust the tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids.
Page 17 Overloading can cause loss of control. Loss of control can result in severe injury or death. Year of construction Model Name **** ****** *** kW YAMAHA MOTOR CO., LTD. Max. Power *** kg 2500 SHINGAI, IWATA, JAPAN Mass In Running Order...
Page 18 For Oceania...
Page 19 25 kPa, (3.6 psi) 25 kPa, (3.6 psi) 22 kPa, (3.2 psi) 22 kPa, (3.2 psi) ( 6 0 0 k g f ) 5880 N 1322 5FU-F816M-20 ( 1 5 k g f ) 37S-F151K-00...
Page 20 UNDER 1P0-F816L-00 1-10...
Page 21 WARNING Fuel vapors can be a fire or explosion hazard. To avoid injury or death, never store fuel or flammable liquids in this storage compartment. Storage should not exceed 0.5 kg (1 lb) 37S-F151F-00 1-11...
Page 22: Safety Information
EBU17431 SAFETY INFORMATION EBU17503 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
Page 23 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 24 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 25 and you can quickly be overcome and unable to save yourself. Also, 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.
Page 26: Description
EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 1. Rear shock absorber assembly spring preload adjusting ring 2. Fuel cock 2. Spark arrester 3. Throttle stop screw 3. Rear storage compartment and tool kit 4. Air filter case 4.
Page 27: Controls And Instruments
EBU17712 Controls and instruments The ATV you have purchased may differ slightly 6 7 8 from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Horn switch 5. Drive select lever 6. Multi-function display 7.
Page 28: Instrument And Control Functions
EBU17733 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: 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.
Page 29: Indicator Lights And Warning Light
4. Neutral indicator light “N” stances or the speedometer does not show the 5. Reverse indicator light “R” speed while riding, have a Yamaha dealer check 6. Park indicator light “P” the speed sensor circuit. 7. On-Command four-wheel-drive/differential gear lock indicator “...
Page 30 EBU17920 On-Command differential gear lock Coolant temperature warning light “ ” indicator “ ” and the On-Command differential This warning light comes on when the engine over- gear lock indicator light “DIFF. LOCK” come on heats. When this occurs during operation, stop the when the On-Command differential gear lock engine as soon as it is safe to do so and allow it to switch is set to the “LOCK”...
Page 31: Multi-Function Display
EBU18037 an hour meter (which shows the total time the Multi-function display key has been turned to “ON”) Odometer and tripmeter modes Pushing the “TRIP/ODO” button switches the dis- play between the odometer mode “ODO” and the tripmeter modes “TRIP A” and “TRIP B” in the fol- lowing order: ODO →...
Page 32: Fuel Gauge
To set the clock 1. Set the display to the clock mode. If the ATV runs out of fuel, move the fuel cock lever 2. Push the “ / ” button until the clock starts to the “RES” position. Approximately 4.5 L (1.19 flashing.
Page 33 EBU18080 If this should happen, remove the battery and Engine stop switch “ ” recharge it. See page 8-51 for battery charging Set this switch to “ ” before starting the engine. information. The engine stop switch controls the ignition and stops the engine when it is running.
Page 34 In circumstances. Changing from two-wheel this case, take the ATV to a Yamaha dealer at the drive to four-wheel drive or vice versa while first opportunity.
Page 35 handle differently. This could distract the oper- ator and increase the risk of losing control and of causing an accident. This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice versa. Select the appropriate drive according to the ter- rain and the conditions.
Page 36 pectedly. This could distract the operator and “LOCK” (four-wheel drive with the differential increase the risk of losing control and causing gear locked): Power is supplied to the rear and an accident. front wheels and the differential gear is locked. Unlike in four-wheel drive, all wheels turn at the EWB00140 same speed.
Page 37 1. Differential gear lock lever 1. On-Command differential gear lock switch “4WD”/“LOCK” 2. On-Command four-wheel-drive switch “2WD”/“4WD” To release the differential gear lock, stop the ATV Stop the ATV, move the differential gear lock lever and push the switch to the “4WD” position. to position (a), and then push the differential gear lock switch in to the “LOCK”...
Page 38: Throttle Lever
Riding before the differential gear lock is proper- ly engaged (e.g., when the indicator and indica- tor light are flashing) will cause the vehicle speed to be limited until engagement is com- plete. When the ATV is in four-wheel-drive differential gear lock, the maximum traveling speed is limit- ed to 35 km/h (22 mi/h).
Page 39: Front Brake Lever
crease the maximum engine power available 3. Tighten the locknut. and the maximum speed of the ATV, turn the EBU18391 adjusting screw in direction (b). Do not turn Front brake lever the adjusting screw out more than 12 mm The front brake lever is located on the right handle- (0.47 in) or the throttle cable could be dam- bar.
Page 40: Drive Select Lever
EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. 1.
Page 41: Fuel
of sparks, open flames, or other sources of ig- nition such as the pilot lights of water heaters 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.
Page 42: Fuel Cock
4.5 L (1.19 US gal, 0.99 Imp.gal) rings, as well as to the exhaust system. 3. Wipe up any spilled fuel immediately. Your Yamaha engine has been designed to use NOTICE: Immediately wipe off spilled fuel regular unleaded gasoline with a research octane with a clean, dry, soft cloth, since fuel may number of 91 or higher.
Page 43 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.
Page 44: Starter (Choke)
Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Arrow mark pointing to “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.
Page 45: Storage Compartments
1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU29252 Storage compartments Insert the projections on the front of the seat into This ATV is equipped with two storage compart- the seat holders and push down on the seat at the ments.
Page 46 The front storage compartment is located at the front right side of the ATV. To access the storage compartment, remove the storage compartment cover by turning it counterclockwise. 1. Front storage compartment The rear storage compartment is located under the seat.
Page 47 When storing any documents in the storage com- partments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartments. Do not exceed the load limit of 0.5 kg (1 lb) for the front storage compartment or 2.0 kg (4 lb) for the rear storage compartment.
Page 48: Front Carrier
2. Position indicator EWB00400 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 49: Auxiliary Dc Jack
EBU19183 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running and the light switch is set to “OFF”.
Page 50 Maximum rated capacity for the auxiliary DC jack: DC 12 V, 10 A (120 W) 5. Turn the accessory on. 6. When the auxiliary DC jack is not being used, cover it with the cap. ECB00120 NOTICE Do not use accessories requiring more than the above maximum capacity.
Page 51: 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 52 ITEM ROUTINE PAGE • 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, 8-39, 8-40, 8-41 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.
Page 53: Fuel
EBU19590 Check that there is no free play in the front brake Final gear oil lever. If there is free play, have a Yamaha dealer Make sure that the final gear oil is at the specified check the brake system.
Page 54: Throttle Lever
If there is any leakage, the brake proper tire pressure may cause severe injury system should be checked by a Yamaha dealer. or death from loss of control or rollover. Tire pressure below the minimum specified could...
Page 55 Recommended tire pressure: Front 25.0 kPa (0.250 kgf/cm², 3.6 psi) Rear 25.0 kPa (0.250 kgf/cm², 3.6 psi) Minimum tire pressure: Front 22.0 kPa (0.220 kgf/cm², 3.2 psi) Rear 22.0 kPa (0.220 kgf/cm², 3.2 psi) Maximum tire seating pressure: 1. Low-pressure tire gauge Front 250 kPa (2.5 kgf/cm², 36 psi) Tire wear limit...
Page 56 After extensive tests, only the tires listed below braking, and comfort. Other tires, rims, sizes, and have been approved for this model by Yamaha combinations may not be appropriate. Motor Manufacturing Corporation of America.
Page 57: Chassis Fasteners
EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.
Page 58: Operation
Read the Owner’s Manual carefully before riding light should come on, if it does not come on, the ATV. If there is a control or function you do not have a Yamaha dealer check the electrical cir- understand, ask your Yamaha dealer. cuit.
Page 59 Position (3): as possible to preserve battery energy. Do not Cold engine start with ambient temperature crank the engine more than 10 seconds on each above 25 °C (80 °F). attempt. Ambient temp./starter (choke) position 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine.
Page 60: Starting A Warm Engine
EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. EBU20441 Operating the drive select lever and driving in reverse ECB00170...
Page 61 6. P (Park) When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the elec- trical circuit. Due to the synchronizing mechanism in the en- gine, the indicator light may not come on until the...
Page 62: Engine Break-In
There is never a more important period in the life of engine break-in period, immediately have a your engine than the first 320 km (200 mi) or 20 Yamaha dealer check the ATV. hours of riding. For this reason, you should read the following material carefully.
Page 63: Parking On A Slope
4. Turn the fuel cock to “OFF”. 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 64 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 65 Never exceed the weight limits shown. An over- just the load in the trailer, if necessary, to reduce loaded ATV can be unstable. the weight on the hitch. If you are carrying cargo and towing a trailer, include the tongue weight in MAXIMUM LOADING LIMIT the maximum ATV load limit.
Page 66: Riding Your Atv
EBU21141 RIDING YOUR ATV...
Page 67: Getting To Know Your Atv
EBU29234 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding Do not operate this ATV or allow anyone else instructions for recreational riding.
Page 68 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 69 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 70 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 5. Helmet Perform the pre-operation checks listed on page 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 71 opening, even when the throttle lever is pushed to Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see box in this section or ve- the maximum engine power available and de- hicle labeling).
Page 72 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of cargo, rider, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 210.0 kg (463 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
Page 73 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 74: Be Careful Where You Ride
To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
Page 75 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do not ways be alert to changing terrain conditions ride on any paved public street, road or motorway. when operating the ATV.
Page 76 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] 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 77: Turning Your Atv
Select a large, flat, unpaved area to become famil- ECB00251 NOTICE iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice Do not shift from low-range to high-range or control of the throttle, brakes, shifting procedures, vice versa without coming to a complete stop.
Page 78: 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 79 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 80 Do not attempt to climb hills until you have mas- If you are climbing a hill and you find that you have tered basic maneuvers on flat ground. Always not properly judged your ability to make it to the check the terrain carefully before attempting any top, you should turn the ATV around while you still hill.
Page 81: Riding Downhill
remount, following the procedure described in the Always check the terrain carefully before 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 82: 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. When this ATV is in “4WD”, all wheels (front and rear) are interconnected by the drive train.
Page 83: 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 84 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 35 cm (14 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.
Page 85 Wash the ATV in fresh water if it has been operat- ed in salt water or muddy conditions. 1. Drive select lever box check hose 1. Air filter case check hose 1. Storage compartment check hose 1. V-belt cooling duct check hose (left front side of ATV) 7-20...
Page 86: Riding Over Rough Terrain
RIDING OVER ROUGH TERRAIN EWB01651 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. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.
Page 87 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 88: What To Do If
WHAT TO DO IF... THE REAR BRAKE IF THE ATV IS IN “2WD” – This section is designed to be a reference guide the ATV may tip over on top of you. Dismount only. Be sure to read each section on riding tech- the ATV on the uphill side.
Page 89: Periodic Maintenance And Adjustment
The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.
Page 90: Owner's Manual And Tool Kit
Put the owner’s tool kit and low-pres- If you do not have the tools or experience required sure tire gauge under the seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s manual 2.
Page 91: 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 92 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 93: 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 94 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 • Replace. Every 4 years •...
Page 95 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours √ √ √ 13 * Rear knuckle pivots • Lubricate with lithium-soap-based grease. √ √ √ 14 * Steering shaft •...
Page 96 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check coolant level and ATV for coolant leakage, √ √ √ √ √ and correct if necessary. Cooling system •...
Page 97 Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.
Page 98: Removing And Installing Panels
EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel B 2.
Page 99 2. Install the seat. To install one of the panels 1. Place the panel in its original position. 8-11...
Page 100 Panel B To remove the panel 1. Remove the carrier top bolts. 1. Carrier bolt (under the fenders) 3. Remove the quick fastener screws, and then pull the panel upward to remove it. 1. Carrier bolt (top) 2. Remove the carrier bolts under the fenders, and then take the carrier off.
Page 101 Tightening torques: Carrier bolt (top): 34 Nm (3.4 m·kgf, 25 ft·lbf) Carrier bolt (under fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Panel D To remove the panel Remove the bolts, and then take the panel off. 1. Quick fastener screw 2.
Page 102: Checking The Spark Plug
To install the panel Place the panel in the original position and install the bolts. Panel E To remove the panel Pull outward on the areas shown. EBU23223 Checking the spark plug The spark plug is an important engine component, which is easy to check.
Page 103 (the ideal color when the ATV is ridden normally). If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-15...
Page 104 2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.
Page 105: Engine Oil And Oil Filter Cartridge
EBU30240 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals spec- ified in the periodic maintenance and lubrication chart.
Page 106 To change the engine oil (with or without oil fil- ter cartridge replacement) 1. Place the ATV on a level surface. 2. Remove panel E. (See page 8-10.) 3. Start the engine, warm it up for several min- utes, and then turn it off. 4.
Page 107 7. Remove the oil filter cartridge with an oil filter wrench. 1. Oil filter wrench An oil filter wrench is available at a nearby Yamaha dealer. 8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
Page 108 1. O-ring 1. Torque wrench Tightening torque: Oil filter cartridge: Make sure that the O-ring is properly seated. 17 Nm (1.7 m·kgf, 12 ft·lbf) 9. Install the new oil filter cartridge with an oil fil- 10. Install panels D and C. ter wrench, and then tighten it to the specified 11.
Page 109: Final Gear Oil
The final gear case must be checked for oil leak- engine and exhaust system have cooled down. age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- ECB00300 dition, the final gear oil level must be checked and...
Page 110 To change the final gear oil 1. Place the ATV on a level surface. 2. Remove the engine guard and the final gear case guard by removing the bolts. 1. Final gear oil filler bolt 2. Gasket 3. Final gear oil 4.
Page 111 1. Final gear oil drain bolt 1. Final gear oil filler bolt 2. Gasket 2. Gasket 3. Final gear oil 5. Install the drain bolt and its new gasket, and 4. Correct oil level then tighten the bolt to the specified torque. Recommended final gear oil: Tightening torque: See page 10-1.
Page 112: Differential Gear Oil
The differential gear case must be checked for oil 3. Differential gear oil leakage before each ride. If any leakage is found, 4. Correct oil level have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil level must be 8-24...
Page 113 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 4. Check the gasket for damage, and replace it if necessary. 5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.
Page 114: Coolant
8. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23470 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.
Page 115 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. [ECB01011] 1. Maximum level mark 2.
Page 116 The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. If the engine overheats, see page 8-61 for fur- ther instructions. EBU23605 To change the coolant EWB01890 WARNING 1. Coolant drain bolt Wait for the engine and radiator to cool before 2.
Page 117 4. Remove the front carrier and panel B. (See page 8-10.) 5. Remove the radiator cap. 1. Coolant reservoir hose 9. After draining the coolant, thoroughly flush the cooling system with clean tap water. 1. Radiator cap 10. Install the coolant drain bolt and its new gas- ket, and then tighten the bolt to the specified 6.
Page 118: Cleaning The Air Filter Element
Do not use hard water or salt water since they are If any leakage is found, have a Yamaha dealer harmful to the engine. [ECB00991] check the cooling system.
Page 119 1. Air filter case check hose 1. Air filter case cover holder 2. Air filter case cover 1. Place the ATV on a level surface. 4. Pull the air filter element out of the air filter 2. Remove the seat. (See page 4-17.) case.
Page 120 1. Air filter element 1. Air filter element frame 2. Sponge material 5. Pull off the air filter element lock plate, and 3. Air filter element lock plate then remove the sponge material from the air 6. Wash the sponge material gently but thor- filter element frame.
Page 121: Cleaning The Spark Arrester
40 hours. It should be cleaned and lubricated more damaged. often if the ATV is operated in extremely dusty ar- 9. Apply Yamaha foam air filter oil or other qual- eas. Each time the air filter element maintenance ity foam air filter oil to the sponge material.
Page 122 1. Bolt 1. Tailpipe 2. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 4. Insert the tailpipe into the muffler and align the muffler. bolt holes. 3. Tap the tailpipe lightly, and then use a wire 5.
Page 123: V-Belt Cooling Duct Check Hose
Always let the exhaust system cool prior to If water drains from the V-belt case after removing touching exhaust components. the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts. EBU23920 V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it.
Page 124: Adjusting The Carburetor
Therefore, most carburetor adjustments should be left to a The engine is warm when it quickly responds to the Yamaha dealer, who has the necessary profes- throttle. sional knowledge and experience. The adjustment 2. Remove panel C. (See page 8-10.) described in the following section, however, may 3.
Page 125: Adjusting The Throttle Lever Free Play
If the specified idling speed cannot be obtained as rection (a). To decrease the throttle lever free described above, have a Yamaha dealer make the play, turn the adjusting bolt in direction (b). adjustment.
Page 126: 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 127: Checking The Front Brake Pads And Rear Brake Friction Plates
(See page 8-58.) sure the lining thickness. If a brake pad is dam- aged or if the lining thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the brake EBU30320 Rear brake friction plates pads as a set.
Page 128: Checking The Brake Fluid Level
1. Minimum level mark Changing the brake fluid Observe these precautions: Have a Yamaha dealer change the brake fluid at When checking the fluid level, make sure that the intervals specified in the TIP after the periodic the top of the brake fluid reservoir is level.
Page 129: Checking The Front Brake Lever Free Play
(0.39 in). If the free play is incorrect, adjust it as fol- free play as shown. If there is free play, have a lows. Yamaha dealer check the brake system. 1. Brake lever free play 1. No brake lever free play 1.
Page 130 If the specified brake lever free play could be ob- tained as described above, skip steps 3-7. 3. Slide the rubber cover back. 1. Locknut 2. Distance A 3. Brake lever free play adjusting bolt 2. To increase the brake lever free play, turn the brake lever free play adjusting bolt in direction (a).
Page 131 (0.87 in) or less. If the specified free play cannot be obtained or if distance B exceeds 22 mm (0.87 in), have a Yamaha dealer check the vehicle. [ECB01150] 6. Tighten the brake cable adjuster locknut. 7. Slide the rubber cover to its original position.
Page 132 1. Locknut 1. Footboard bolt A 2. Adjusting bolt 2. Footboard bolt B 3. Turn the adjusting bolt in or out until the brake Tightening torques: pedal height is within the specified limits. Footboard bolt A: 4. Tighten the locknut. 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Footboard bolt B: Tightening torque:...
Page 133: 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 re- placed by a Yamaha dealer. 8-45...
Page 134: Brake Light Switches
The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. Turn the adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a).
Page 135: Checking And Lubricating The Cables
If a cable is damaged or does not move pivots should be lubricated if necessary. smoothly, have a Yamaha dealer check or replace Recommended lubricants: Front brake lever: Recommended lubricant:...
Page 136: Checking And Lubricating The Brake Pedal
The operation of the brake pedal should be in a wheel hub or if a wheel does not turn smoothly, checked before each ride, and the pedal pivot have a Yamaha dealer check the wheel hub bear- should be lubricated if necessary. ings.
Page 137: Lubricating The Drive Shaft Universal Joint
Front EBU24972 1. Grease nipple Lubricating the drive shaft universal joint Rear The drive shaft universal joint must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. For parts equipped with a grease nipple, use a grease gun.
Page 138: Checking The Stabilizer Bushes
The rear knuckle pivots must be lubricated at the EBU25092 Lubricating the steering shaft intervals specified in the periodic maintenance and The steering shaft must be lubricated by a Yamaha lubrication chart. dealer at the intervals specified in the periodic maintenance and lubrication chart.
Page 139: Battery
EWB02160 WARNING For parts equipped with a grease nipple, use a Battery electrolyte is poisonous and danger- grease gun. ous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, Recommended lubricant: eyes or clothing. Always shield your eyes Lithium-soap-based grease when working near batteries.
Page 140 3. Disconnect the negative battery lead first, To charge the battery then the positive battery lead by removing Have a Yamaha dealer charge the battery as soon their bolt. NOTICE: When removing the bat- as possible if it seems to have discharged. Keep in...
Page 141: Replacing A Fuse
To install the battery 4. Install the seat. (See page 4-17.) EBU25326 Replacing a fuse Be sure the battery is fully charged. The main fuse and the fuse box are located under 1. Place the battery in its compartment. the seat. (See page 4-17.) 2.
Page 142 2. Remove the blown fuse, and then install a 2 3 4 5 6 new fuse of the specified amperage. WARNING! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical system, which could lead to a fire.
Page 143: Replacing A Headlight Bulb
4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25481 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.
Page 144: Adjusting A Headlight Beam
ECB00690 moistened with alcohol or thinner. [ECB00651] NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).
Page 145: Replacing The Tail/Brake Light Bulb
1. Headlight beam adjusting screw 1. Tail/brake light assembly 2. Nut EBU25622 2. Remove the tail/brake light bulb holder (to- Replacing the tail/brake light bulb gether with the bulb) by turning it counter- If the tail/brake light bulb burns out, replace it as clockwise.
Page 146: Removing A Wheel
1. Tail/brake light assembly 1. Tail/brake light bulb holder 2. Tail/brake light bulb holder 2. Tail/brake light bulb 3. Remove the burnt-out bulb by pushing it in 4. Insert a new bulb into the bulb holder, push it and turning it counterclockwise. in, and then turn it clockwise until it stops.
Page 147: Installing A Wheel
Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Wheel nut 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 1.
Page 148: 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 149: 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 150 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 151: Cleaning And Storage
EBU25860 CLEANING AND STORAGE EBU25881 tion of wheel bearings, brakes, transmis- Cleaning sion seals and electrical devices. Many Frequent, thorough cleaning of your ATV will not expensive repair bills have resulted from only enhance its appearance but will improve its improper high-pressure detergent applica- general performance and extend the useful life of tions such as those available in coin-oper-...
Page 152: Storage
EBU25933 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inder, piston rings, etc.
Page 153 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 154: Specifications
EBU25960 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 1993 mm (78.5 in) Liquid cooled 4-stroke, SOHC Overall width: Cylinder arrangement: 1093 mm (43.0 in) Forward-inclined single cylinder Overall height: Displacement: 1120 mm (44.1 in) 421 cm³ Bore × stroke: Seat height: 84.5 ×...
Page 155 SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- 0.38 L (0.40 US qt, 0.33 Imp.qt) Differential gear oil: Type: YFM450FAA Yamaha Friction Modified Shaft Drive Gear 50 ˚C Oil (Part No.: ACC-SHAFT-LU-00) or SAE 80 API GL-4 Hypoid gear oil...
Page 156 Spark plug (s): Trail: 8.5 mm (0.33 in) Manufacturer/model: Front tire: NGK/DR8EA Spark plug gap: Type: 0.6–0.7 mm (0.024–0.028 in) Tubeless Clutch: Size: AT25 x 8-12 Clutch type: Manufacturer/model: Wet, centrifugal automatic YFM450FAA CHENG SHIN/C-828 Transmission: YFM45FGA MAXXIS/MU13 Primary reduction system: Rear tire: V-belt Type:...
Page 157 Rear: Rear suspension: 22.0 kPa (0.220 kgf/cm², 3.2 psi) Type: Front wheel: Double wishbone Wheel type: Spring/shock absorber type: Panel wheel Coil spring/oil damper Rim size: Wheel travel: 12 x 6.0AT 180 mm (7.1 in) Rear wheel: Electrical system: Wheel type: Ignition system: Panel wheel DC CDI...
Page 158 Coolant temperature warning light: Park indicator light: On-Command four-wheel-drive/differential gear lock indicator: High-range indicator light: Low-range indicator light: Differential gear lock indicator light: Fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Ignition fuse: 10.0 A Auxiliary DC jack fuse: 10.0 A Backup fuse:...
Page 159: Consumer Information
Record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number (front left side)
Page 160 EBU26050 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 Yamaha deal- 11-2...
Page 161 INDEX Accessories and loading ..........6-6 Differential gear oil ..........5-3, 8-24 Accessories, auxiliary jack ........... 4-22 Drive select lever ............4-13 Air filter element, cleaning ..........8-30 Drive select lever and driving in reverse ......6-3 Axle boots ..............8-45 Drive select lever safety system cable, adjusting ..
Page 162 Riding your ATV ............. 7-1 Identification numbers ..........11-1 Indicator lights and warning light ........4-2 Safety information ............2-1 Instruments, lights and switches ........5-7 Seat ................4-17 Shock absorber assemblies, adjusting the front and rear ................4-21 Label locations ............... 1-1 Spark arrester, cleaning ..........
Page 164 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2010.06-0.4×1 CR...

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