Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45FGW WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-20-17 1D9-F8199-13...
Page 2 EBU17091...
Page 3 Yamaha experience in the production of fine sporting, touring, and pace-setting 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 4 EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 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: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or...
Page 5 EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.
Page 6: Table Of Contents
Throttle lever ..........4-11 EWB00010 WARNING Speed limiter ..........4-12 Front brake lever ........4-13 Indicates a potential hazard that could result in serious injury or death. Brake pedal and rear brake lever .....4-14 Drive select lever ........4-14 Recoil starter ..........4-15 Fuel tank cap ..........4-16 EBU17420 Fuel ............4-16 TABLE OF CONTENTS...
Page 7 Tires ............5-7 RIDING OVER ROUGH TERRAIN....7-30 Measuring the tire pressure ....... 5-8 SLIDING AND SKIDDING ......7-31 Tire wear limit ..........5-9 WHAT TO DO IF........7-32 Chassis fasteners ........5-9 WHAT TO DO..........7-33 Instruments, lights and switches ....5-9 PERIODIC MAINTENANCE AND MINOR OPERATION ..........
Page 8 Checking the wheel bearings ....8-46 Noise regulation ........11-3 Lubricating the drive shaft universal Maintenance record ........11-4 joint ............8-46 YAMAHA MOTOR CORPORATION, Checking the stabilizer bushes ....8-47 U.S.A. ATV LIMITED WARRANTY ..11-5 Lubricating the upper and lower arm YAMAHA EXTENDED SERVICE pivots ............
Page 9: Safety Information
EBU17430 SAFETY INFORMATION EBU17482 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 10 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 11 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 12 EWB00021 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- POTENTIAL HAZARD oline in your eyes, seek medical help Improper handling of gasoline. immediately. If gasoline spills on your skin, WHAT CAN HAPPEN wash with soap and water.
Page 13 WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad- equate ventilation.
Page 14: Location Of The Warning And Specification Labels
EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
Page 15 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 18: 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. Recoil starter 3. Storage compartment and tool kit 4. Throttle stop screw 4. Spark plug 5.
Page 19: Controls And Instruments
EBU17712 NOTE: 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. Starter (choke) 4. Drive select lever 5. Multifunction meter unit 6. Main switch 7.
Page 20: Instrument And Control Functions
EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 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 1.
Page 21: Indicator Lights And Warning Light
NOTE: Indicator lights and warning light If the indicator light flashes or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. EBU17860 Neutral indicator light “ ” This indicator light comes on when the transmis- sion is in the neutral position.
Page 22 EBU17961 EBU17980 On-Command four-wheel-drive/differential High-range indicator light “ ” gear lock indicator “ ”/“ ” This indicator light comes on when the transmis- DIFF. LOCK The On-Command four-wheel-drive indicator “ ” sion is in the high-range position. comes on when the On-Command four-wheel- EBU17990 drive switch is set to the “4WD”...
Page 23: Multifunction Display
EBU18031 a clock Multifunction display an hour meter (which shows the total time the 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 “A” and “B” in the following order: ODO →...
Page 24: Fuel Gauge
To set the clock NOTE: 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 25 EBU18080 ECB00040 Engine stop switch “ ” CAUTION: Set this switch to “ ” before starting the engine. Do not use the headlights with the engine The engine stop switch controls the ignition and turned off for an extended period of time, oth- stops the engine when it is running.
Page 26 This ATV is equipped with a switch to change from indicate a malfunction in the electrical system. In two-wheel drive to four-wheel drive and vice-versa. this case, take the ATV to a Yamaha dealer at the Select the appropriate drive according to the ter- first opportunity.
Page 27 “4WD” (four-wheel drive): Power is supplied to EWB00120 WARNING the rear and front wheels. To change from two-wheel drive to four-wheel POTENTIAL HAZARD drive, stop the ATV and push the switch in to the Changing from two-wheel drive to four- “4WD”...
Page 28 EBU18243 To lock the differential gear in four-wheel drive, On-Command differential gear lock switch make sure the On-Command four-wheel-drive “4WD”/“LOCK” switch is pushed in to the “4WD” position. This 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.
Page 29 WHAT CAN HAPPEN The ATV handles differently in four-wheel drive than in differential gear lock in some circumstances. Changing from four-wheel drive to differential gear lock or vice-versa while moving may cause the ATV to handle differently unexpectedly. This could distract the operator and increase the risk of losing control and causing an accident.
Page 30: Throttle Lever
EWB00101 Riding before the differential gear lock is proper- WARNING ly engaged (e.g., when the indicator and indica- tor light are flashing) will cause the engine speed POTENTIAL HAZARD to be limited until engagement is complete. Riding too fast while the ATV is in four- When the ATV is in four-wheel-drive differential wheel-drive differential gear lock.
Page 31: Speed Limiter
Check the operation of the throttle lever be- fore you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. EBU18311 Speed limiter Your ATV was delivered with an adjustable speed limiter.
Page 32: Front Brake Lever
HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). (See page 8-37.) EBU18391 Front brake lever The front brake lever is located on the right handle- bar.
Page 33: Brake Pedal And Rear Brake Lever
EBU18442 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 handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.
Page 34: Recoil Starter
1. Drive select lever 1. Recoil starter EWB00290 EBU18680 WARNING Recoil starter Firmly grasp the handle and pull slightly until en- POTENTIAL HAZARD gagement can be felt. Then pull forcefully, being Starting the engine without setting the drive careful not to pull the rope all the way out. select lever to the park position.
Page 35: Fuel Tank Cap
EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Fuel level 2. Fuel tank filler tube Recommended fuel: UNLEADED GASOLINE ONLY 1. Fuel tank cap Fuel tank capacity: EBU18730 15.0 L (3.96 US gal) (3.30 Imp.gal) Fuel Fuel reserve amount: Make sure that there is sufficient fuel in the tank.
Page 36: Fuel Cock
HOW TO AVOID THE HAZARD Your Yamaha engine has been designed to use Do not overfill the fuel tank. Be careful not to regular unleaded gasoline with a pump octane...
Page 37 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 38: 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 39: Storage Compartment
1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18941 Storage compartment Insert the projections on the front of the seat into The storage compartment is located under the the seat holders and push down on the seat at the seat.
Page 40: Front Carrier
ECB00130 NOTE: CAUTION: There is a check hose at the bottom of the storage Do not store metal or sharply edged objects, compartment. If any water collects in this hose, re- like tools, in the storage compartment. If they move the hose, empty it, and then install it. must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartment.
Page 41: Rear Carrier
Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspen- NOTE: sion, and in direction (b) to decrease the spring A special wrench can be obtained at a Yamaha preload and thereby soften the suspension. dealer to make this adjustment. 4-22...
Page 42: Auxiliary Dc Jack
WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorber assem- blies on the left and right side to the same setting.
Page 43 Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A) 4. When the auxiliary DC jack is not being used, cover it with the cap. ECB00120 CAUTION: Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to 1.
Page 44: Pre-Operation Checks
Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
Page 45 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check lever free play, and adjust if necessary. Rear brake • Check brake pads for wear, and replace if necessary. 5-5, 8-38, 8-39, 8-41 •...
Page 46 EWB00470 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Own- er’s Manual.
Page 47: Fuel
EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. Make sure that the final gear oil is at the specified (See page 4-16.) level. Add oil as necessary. (See page 8-21.) EWB00500 WARNING EBU19600 Differential gear oil POTENTIAL HAZARD...
Page 48: Front And Rear Brakes
Check that there is no free play in the front brake If there is any leakage, the brake system should be lever. If there is free play, have a Yamaha dealer checked by a Yamaha dealer. check the brake system.
Page 49: Throttle Lever
Do not ride the ATV if you find any prob- lem with the brakes. If a problem cannot be corrected by the adjustment procedures pro- vided in this manual, have a Yamaha dealer check for the cause. EBU19761 Throttle lever Check the operation of the throttle lever.
Page 50: Tires
HOW TO AVOID THE HAZARD Rear: The tires listed below have been approved 25.0 kPa (3.6 psi) (0.250 kgf/cm²) by Yamaha Motor Manufacturing Corpora- • Check and adjust tire pressures when tion of America for this model. Other tire the tires are cold.
Page 51: Measuring The Tire Pressure
Tire pressure below the minimum speci- NOTE: fied could cause the tire to dislodge from The low-pressure tire gauge is included as stan- the rim under severe riding conditions. dard equipment. Make two measurements of the Minimum tire pressure: tire pressure and use the second reading. Dust or Front: dirt in the gauge could cause the first reading to be 22.0 kPa (3.2 psi) (0.220 kgf/cm²)
Page 52: Tire Wear Limit
Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Tire wear limit Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) EBU19840 Chassis fasteners Rear...
Page 53: Operation
Read the Owner’s Manual carefully. If there is prior to operating the engine for the first time. a control or function you do not understand, ask your Yamaha dealer. 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “...
Page 54 3. Shift the drive select lever into the neutral or Ambient temp./starter (choke) position park position. The corresponding indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. NOTE: The engine can be started under the following con-...
Page 55: Starting A Warm Engine
If the battery is discharged, pull the recoil starter EBU20291 Starting a warm engine to start the engine. Follow the same procedure as for starting a cold 7. If the engine is started with the starter (choke) engine, with the exception that the starter (choke) in position (1), the starter (choke) should be is not required when the engine is warm.
Page 56 The drive select lever cannot be shifted into or from should come on. If the indicator light does not reverse or park without applying the brake pedal. come on, have a Yamaha dealer check the elec- trical circuit. 1. Bring the ATV to a complete stop.
Page 57: Engine Break-In
There is never a more important period in the life of If any engine trouble should occur during the your engine than the first 20 hours of riding. For engine break-in period, immediately have a this reason, you should read the following material Yamaha dealer check the ATV. carefully.
Page 58: Parking
Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of gen- 1. Bring the ATV to a stop by applying the uine Yamaha accessories. Other accessories brakes.
Page 59 Yamaha to test all non- Never exceed the weight limits shown. An over- Yamaha accessories, nor control over their qual- loaded ATV can be unstable. ity or suitability. Choose a genuine Yamaha ac- MAXIMUM LOADING LIMIT...
Page 60 the weight on the hitch. If you are carrying cargo EWB00750 WARNING and towing a trailer, include the tongue weight in the maximum ATV load limit. POTENTIAL HAZARD Load cargo on the carriers as close to the center Overloading this ATV or carrying or towing of the ATV as possible.
Page 61: Riding Your Atv
EBU21131 RIDING YOUR ATV...
Page 62: Getting To Know Your Atv
EWB00010 ular attention to the safety information on pages WARNING 1-1–1-5. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. RIDE WITH CARE AND GOOD JUDGEMENT EBU21471 Get training if you are inexperienced.
Page 63 Yamaha. They should then ry or death of the child. regularly practice the skills learned in the HOW TO AVOID THE HAZARD course and the operating techniques de- A child under 16 should never operate an scribed in this Owner’s Manual.
Page 64 This ATV is designed to carry operator and car- go only – passengers prohibited. EWB00910 WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger.
Page 65 Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet EWB00920 WARNING that fits properly. You should also wear: POTENTIAL HAZARD eye protection (goggles or face shield) Operating this ATV without wearing an ap- gloves proved motorcycle helmet, eye protection boots and protective clothing.
Page 66 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. by the influence of alcohol or drugs. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.
Page 67 EWB00950 Do not operate at speeds too fast for your skills WARNING or the conditions. EWB00960 POTENTIAL HAZARD WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Operating this ATV at speeds too fast for Use of improper tires on this ATV, or opera- your skills or the conditions.
Page 68 Speed limiter Loading and accessories For riders less experienced with this model, the Use extra caution when riding the ATV with addi- throttle lever housing is equipped with a speed lim- tional loads, such as accessories or cargo. The iter. The speed limiter keeps the throttle from fully ATV’s handling may be adversely affected.
Page 69 EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
Page 70 During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op- Removing even one hand or foot can reduce eration, otherwise they may contact the rear your ability to control the ATV or could wheels. cause you to lose your balance and fall off of the ATV.
Page 71 Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo- nents designed for use on this ATV and should be installed and used according to instructions.
Page 72: Be Careful Where You Ride
Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system.
Page 73 HOW TO AVOID THE HAZARD EWB01030 WARNING Always avoid paved surfaces, including sidewalks, driveways, parking lots and POTENTIAL HAZARD streets. Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one.
Page 74 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
Page 75 HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. EWB01060 WARNING POTENTIAL HAZARD...
Page 76 Do not ride in areas posted “no trespassing”. be hot when riding and afterwards; do not allow Do not ride on private property without getting per- skin or clothing to come in contact with these com- mission. ponents. With the engine idling, shift the drive select lever into the low-range position or the high-range posi- tion.
Page 77: Turning Your Atv
TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off-road Always follow proper procedures for turning in 2WD or 4WD, the two rear wheels turn together as described in this Owner’s Manual. Prac- at the same speed. Furthermore, when riding in tice turning at low speeds before attempting 4WD-LOCK (“DIFF.
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 oped your skill. In all cases avoid inclines with slip- pery or loose surfaces, or obstacles that might cause you to lose control. EWB01090 WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The ATV can overturn more easily on ex- tremely steep hills than on level surfaces or small hills.
Page 80 It is important when climbing a hill to make sure HOW TO AVOID THE HAZARD that your weight is transferred forward on the ATV. Always follow proper procedures for climb- This can be accomplished by leaning forward and, ing hills as described in this Owner’s Manu- on steeper inclines, standing on the footboards and leaning forward over the handlebars.
Page 81 7-21...
Page 82 If you are climbing a hill and you find that you have When crossing the side of a hill: not properly judged your ability to make it to the Always follow proper procedures as de- top, you should turn the ATV around while you still scribed in the Owner’s Manual.
Page 83 If you start to roll backwards, DO NOT apply either If you begin rolling backwards: brake abruptly. If you are in 2WD, apply only the Keep weight uphill. front brake. If you are in 4WD or 4WD-LOCK, be- 2WD: Never apply the rear brake while roll- cause all wheels are interconnected by the drive ing backwards.
Page 84: Riding Downhill
RIDING DOWNHILL Whenever possible, ride your ATV straight down- When riding your ATV downhill, shift your weight hill. Avoid sharp angles which could allow the ATV as far to the rear and uphill side of the ATV as pos- to tip or roll over. Carefully choose your path and sible.
Page 85 7-25...
Page 86: Crossing A Slope
CROSSING A SLOPE HOW TO AVOID THE HAZARD Traversing a sloping surface on your ATV requires Never attempt to turn the ATV around on any you to properly position your weight to maintain hill until you have mastered the turning tech- proper balance.
Page 87 7-27...
Page 88: Crossing Through Shallow Water
CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
Page 89 1. Air filter case check hose ECB00280 CAUTION: After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the storage compartment check hose.
Page 90: Riding Over Rough Terrain
1. V-belt case drain plug 1. Drive select lever box check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident.
Page 91: Sliding And Skidding
WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.
Page 92: What To Do If
If the rear wheels of your ATV start to slide side- EWB01170 WARNING ways, control can usually be regained (if there is room to do so) by steering in the direction of the POTENTIAL HAZARD slide. Applying the brakes or accelerating is not Skidding or sliding improperly.
Page 93: What To Do
WHAT TO DO... If your ATV is traversing a sloping surface: If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.
Page 94: Periodic Maintenance And Minor Repair
Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.
Page 95 Yamaha ATV dealer. additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.
Page 96: 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 97 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 98: General Maintenance And Lubrication Chart
EBU21862 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
Page 99 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Upper and lower √ √ √ • Lubricate with lithium-soap-based grease. arm pivots • Check for wear, cracks or other damage, and re- √...
Page 100 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Engine oil filter car- √ √ √ • Replace. tridge √ √ √ Engine oil strainer • Clean. •...
Page 101 EBU23070 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 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.
Page 102: Removing And Installing Panels
EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 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.
Page 103 To install one of the panels 1. Place the panel in its original position. 8-10...
Page 104 Panel B To remove the panel Remove the bolt, and then take the panel off. 1. Bolt 2. Panel B To install the panel Place the panel in the original position and install the bolt. ECB00380 CAUTION: When installing the panel, be sure not to pinch 2.
Page 105 Panel C 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 106 Panel E To remove the panel Remove the bolts, and then take the panel off. 1. Quick fastener screw 2. Panel C To install the panel 1. Place the panel in the original position, and 1. Panel E then install the quick fastener screws. 2.
Page 107: Checking The Spark Plug
EBU23221 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 108 Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.
Page 109: Engine Oil And Oil Filter Cartridge
NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4.
Page 110 1. Engine oil filler cap 1. Dipstick 2. Maximum level mark 6. Insert the dipstick into the filler hole (without 3. Minimum level mark screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the minimum and maximum level marks.
Page 111 To change the engine oil (with or without oil fil- NOTE: ter cartridge replacement) Skip steps 6–10 if the oil filter cartridge is not being 1. Remove panel F. (See page 8-9.) replaced. 2. Place the ATV on a level surface. 6.
Page 112 1. Oil filter wrench 1. O-ring NOTE: NOTE: An oil filter wrench is available at a nearby Yamaha Make sure that the O-ring is properly seated. dealer. 9. Install the new oil filter cartridge with an oil fil- 8. Apply a thin coat of engine oil to the O-ring of ter wrench, and then tighten it to the specified the new oil filter cartridge.
Page 113 12. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.43 US qt) (2.02 Imp.qt) With oil filter cartridge replacement: 2.40 L (2.54 US qt) (2.11 Imp.qt) 1.
Page 114: Final Gear Oil
The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified 1.
Page 115 To change the final gear oil 1. Remove the engine guard and the final gear case guard by removing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 1.
Page 116: Differential Gear Oil
CAUTION: leakage before each ride. If any leakage is found, Be sure no foreign material enters the final have a Yamaha dealer check and repair the ATV. gear case. In addition, the differential gear oil level must be 7. Install the oil filler bolt, and then tighten it to the checked and the oil changed as follows at the in- specified torque.
Page 117: To Change Differential Gear Oil
To check the differential gear oil level 3. If the oil is below the brim of the filler hole, add 1. Place the ATV on a level surface. sufficient oil of the recommended type to raise it to the correct level. NOTE: 4.
Page 118 1. Differential gear oil drain bolt 1. Differential gear oil 2. Differential gear oil filler bolt 4. Install the drain bolt, and then tighten it to the 3. Correct oil level specified torque. Recommended differential gear oil: Tightening torque: See page 10-1. Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ECB00410...
Page 119: Coolant
Tightening torque: NOTE: Differential gear oil filler bolt: The coolant should be between the minimum and 23 Nm (2.3 m·kgf, 17 ft·lbf) maximum level marks. 7. 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...
Page 120 If water has been added to the coolant, have cap. a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- 1. Place the ATV on a level surface.
Page 121 4. Remove the front carrier and panel C. (See page 8-9.) 5. Remove the radiator cap. 1. Coolant drain bolt 1. Radiator cap 6. Remove panel D. (See page 8-9.) 7. Remove the coolant reservoir cap. 8. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the cool- ant reservoir.
Page 122 13. Pour the recommended coolant into the radia- tor until it is full. Antifreeze/water mixture ratio: Recommended antifreeze: High-quality ethylene glycol antifreeze con- taining corrosion inhibitors for aluminum en- gines Coolant quantity: Radiator capacity (including all routes): 1.30 L (1.37 US qt) (1.14 Imp.qt) 1.
Page 123: Cleaning The Air Filter Element
16. Start the engine, and then check for coolant leakage. NOTE: If any leakage is found, have a Yamaha dealer check the cooling system. 1. Air filter case check hose 17. Install the panels and the front carrier.
Page 124 1. Air filter case holder 1. Air filter element 2. Air filter case cover 4. Pull off the lock plate, and then remove the 3. Pull the air filter element out of the air filter sponge material from the air filter element case.
Page 125 1. Air filter element frame 2. Sponge material 8. Apply Yamaha foam air filter oil or other qual- 3. Air filter element lock plate ity foam air filter oil to the sponge material. 5. Wash the sponge material gently but thor- NOTE: oughly in solvent.
Page 126: Cleaning The Spark Arrester
EBU23881 NOTE: Cleaning the spark arrester The air filter element should be cleaned every 20– Be sure the exhaust pipe and muffler are cool be- 40 hours. It should be cleaned and lubricated more fore cleaning the spark arrester. often if the ATV is operated in extremely dusty ar- 1.
Page 127: V-Belt Cooling Duct Check Hose
WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components.
Page 128: V-Belt Case Drain Plug
If water drains from the V-belt case after removing most carburetor adjustments should be left to a the plug, have a Yamaha dealer check the ATV as Yamaha dealer, who has the necessary profes- the water may affect other engine parts.
Page 129: Adjusting The Engine Idling Speed
The engine is warm when it quickly responds to the throttle. NOTE: 2. Remove panel D. (See page 8-9.) If the specified idling speed cannot be obtained as 3. Attach the tachometer to the spark plug lead. described above, have a Yamaha dealer make the adjustment. 8-36...
Page 130: Adjusting The Throttle Cable Free Play
(b). must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. 8-37...
Page 131: Adjusting The Drive Select Lever Safety System Cable
EBU26460 aged or if the lining thickness is less than 1.0 mm Rear brake pads (0.04 in), have a Yamaha dealer replace the brake Each rear brake pad is provided with wear indica- pads as a set. tor grooves, which allow you to check the brake pad wear without having to disassemble the brake.
Page 132: Checking The Brake Fluid Level
Before riding, check that the brake fluid is above peared, have a Yamaha dealer replace the brake the minimum level mark and replenish if neces- pads as a set. sary. A low brake fluid level may indicate worn brake pads and/or brake system leakage.
Page 133: Changing The Brake Fluid
To check the rear brake fluid level, remove panel Changing the brake fluid C. (See page 8-9.) Have a Yamaha dealer change the brake fluid at Observe these precautions: the intervals specified in the NOTE after the peri- When checking the fluid level, make sure that odic maintenance and lubrication chart.
Page 134: Checking The Front Brake Lever Free Play
After servicing: free play of zero mm (zero in) as shown. If the free Make sure the brakes operate smoothly play is incorrect, have a Yamaha dealer check the and that the free play is correct. brake system. Make sure the brakes do not drag.
Page 135 2. Brake lever free play adjusting bolt 3. Tighten the locknut. If the correct free play cannot be obtained, have a Yamaha dealer adjust it. NOTE: When adjusting the rear brake lever free play: Be sure not to step on the brake pedal.
Page 136: Axle Boots
Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart.
Page 137: 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. 1. Remove panel B. (See page 8-9.) NOTE: 1. Front axle boot (each side)
Page 138: Checking And Lubricating The Cables
If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Lithium-soap-based grease (all-purpose grease)
Page 139: Checking And Lubricating The Brake Pedal
Yamaha dealer check the wheel bearings. NOTE: To access the brake pedal pivot, remove panel B.
Page 140: Checking The Stabilizer Bushes
Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bush- es if necessary. EBU25040 Lubricating the upper and lower arm...
Page 141: Lubricating The Steering Shaft
EWB02140 To charge the battery WARNING Have a Yamaha dealer charge the battery as soon POTENTIAL HAZARD as possible if it seems to have discharged. Keep in Failure to handle batteries or battery electro- mind that the battery tends to discharge more lyte carefully.
Page 142 To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat- tery. 8-49...
Page 143: Replacing A Fuse
EBU25313 Replacing a fuse 1. Main fuse 2. Spare main fuse 1. Main fuse 2. Fuse box 8-50...
Page 144 ECB00640 CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A 1. Headlight fuse Headlight fuse: 2.
Page 145: Replacing A Headlight Bulb
4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU26892 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
Page 146 3. Remove the headlight bulb holder assembly WHAT CAN HAPPEN by turning it counterclockwise. You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it.
Page 147: Adjusting A Headlight Beam
If the tail/brake light bulb burns out, replace it as follows. EBU25550 Adjusting a headlight beam 1. Remove the tail/brake light assembly by re- ECB00690 moving the nuts together with the washers. CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 8-54...
Page 148 1. Tail/brake light assembly 1. Tail/brake light assembly 2. Nut 2. Tail/brake light bulb holder 2. Remove the bulb holder (together with the 3. Remove the defective bulb by pushing it in bulb) by turning it counterclockwise. and turning it counterclockwise. 8-55...
Page 149: Removing A Wheel
1. Tail/brake light bulb holder 1. Wheel nut 2. Tail/brake light bulb 2. Elevate the ATV and place a suitable stand 4. Insert a new bulb into the bulb holder, push it under the frame. in, and then turn it clockwise until it stops. 3.
Page 150 Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Tapered nut 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques.
Page 151: Troubleshooting
However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.
Page 152: 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 153 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: 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 154: Cleaning And Storage
EBU25860 CLEANING AND STORAGE EBU25870 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.
Page 155: Storage
WHAT CAN HAPPEN Long-term Wet brakes may have reduced stopping abil- Before storing your ATV for several months: ity, increasing the chance of an accident. 1. Follow all the instructions in the “Cleaning” HOW TO AVOID THE HAZARD section of this chapter. Test the brakes after washing.
Page 156 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-48.
Page 157: Specifications
EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 10.00 :1 Overall length: Starting system: 1993 mm (78.5 in) Electric and recoil starter Overall width: Lubrication system: 1093 mm (43.0 in) Wet sump Overall height: Engine oil: 1120 mm (44.1 in) Seat height: Type: 830 mm (32.7 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase:...
Page 158 With oil filter cartridge replacement: Type x quantity: 2.40 L (2.54 US qt) (2.11 Imp.qt) BSR33 x 1 Final gear oil: Spark plug (s): Type: Manufacturer/model: SAE80 API GL-4 Hypoid gear oil NGK/DR8EA Quantity: Spark plug gap: 0.16 L (0.17 US qt) (0.14 Imp.qt) 0.6–0.7 mm (0.024–0.028 in) Differential gear oil: Clutch:...
Page 159 Caster angle: Rear: 2.5 ° 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Trail: Maximum: 8.5 mm (0.33 in) Front: Front tire: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Rear: Type: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Tubeless Front wheel: Size: AT25 x 8-12 Wheel type: Manufacturer/model: Panel wheel...
Page 160 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Neutral indicator light: Double wishbone Spring/shock absorber type: Reverse indicator light: Coil spring/oil damper Wheel travel: Coolant temperature warning light: 160 mm (6.3 in) Rear suspension: Park indicator light: Type: Double wishbone On-Command four-wheel-drive/differential gear lock...
Page 161 Four-wheel-drive motor fuse: 3.0 A 10-5...
Page 162: Consumer Information
Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
Page 163 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 164: Noise Regulation
EBU26060 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 ul- timate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Page 165: Maintenance Record
EBU26080 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 166: 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 167 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 168: Yamaha Extended Service (Y.e.s.)
Yamaha people who handle your warranty – and it 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 169 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 170 EBU26132 11-9...
Page 171 INDEX Accessories and loading ..........6-6 Differential gear lock indicator light ........ 4-3 Accessories, auxiliary jack ........... 4-23 Differential gear oil ..........5-4, 8-23 Air filter element, cleaning ..........8-30 Drive select lever ............4-14 Axle boots ..............8-43 Drive select lever and driving in reverse ......6-3 Drive select lever safety system cable, adjusting ..
Page 172 Part locations ..............3-1 Pre-operation check list ..........5-1 Identification numbers ..........11-1 Indicator lights and warning light ........4-2 Instruments, lights and switches ........5-9 Recoil starter ..............4-15 Reverse indicator light ............ 4-2 Riding your ATV ............. 7-1 Key identification number ..........
Page 173 Valve clearance ............8-37 V-belt case drain plug ..........8-35 V-belt cooling duct check hose ........8-34 Vehicle identification number ........11-1 Warranty, extended ............11-7 Warranty, limited ............11-5 Wheel bearings, checking ..........8-46 Wheel, installing ............8-56 Wheel, removing ............8-56...
Page 174 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN USA 2006.04-1.4×1 CR...

This manual is also suitable for:

Grizzly yfm45fgw

Yamaha GRIZZLY 450 Owner's Manual

Quick Links

Troubleshooting

Related Manuals for Yamaha GRIZZLY 450

Summary of Contents for Yamaha GRIZZLY 450

This manual is also suitable for:

Table of Contents