Yamaha YFZ45RB Owner's Manual
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Yamaha YFZ45RB Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFZ45RB
YFZ45RSEB
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-25-19
18P-28199-16

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Summary of Contents for Yamaha YFZ45RB

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFZ45RB YFZ45RSEB WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-25-19 18P-28199-16...
  • Page 2 EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 3 Congratulations on your purchase of the Yamaha YFZ45RB/YFZ45RSEB. 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 4: Important Manual Information

    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 5: Important Notice

    Please check your local riding laws and regulations before operating this ATV. EBU17382 YFZ45RB/YFZ45RSEB OWNER’S MANUAL ©2011 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2011 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

  • Page 6: Table Of Contents

    Clutch lever ..........4-5 EWB00011 WARNING Brake lever ..........4-6 Indicates a hazardous situation which, if not Brake pedal ..........4-6 Parking brake lever ........4-7 avoided, could result in death or serious injury. Shift pedal ...........4-8 Fuel tank cap ..........4-8 Fuel .............4-9 EBU17420 Seat ............4-11 TABLE OF CONTENTS Adjusting the front shock absorber...
  • Page 7 Shifting ............6-2 General maintenance and Engine break-in .......... 6-4 lubrication chart ........8-5 Parking ............6-4 Removing and installing the cowling and Parking on a slope ........6-5 panels ............8-9 Accessories and loading ......6-6 Checking the spark plug ......8-15 Engine oil and oil filter element ....8-16 RIDING YOUR ATV ........
  • Page 8 Checking and lubricating the brake YAMAHA MOTOR CORPORATION, pedal ............8-42 U.S.A. ATV LIMITED WARRANTY ..11-6 Checking the wheel hub bearings .... 8-42 YAMAHA EXTENDED SERVICE Lubricating the swingarm pivots ....8-43 (Y.E.S.) ...........11-8 Lubricating the upper and lower arm pivots ............

  • Page 9: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 10 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 11 Certification of Compliance This ATV complies with applicable provisions of ANSI/SVIA 1-2010 and is subject to an approved ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product Safety Commission. YAMAHA MOTOR CORPORATION U.S.A. 6555 Katella Avenue, Cypress, California 90630-5101, U.S.A.
  • Page 12 WARNING PREMIUM UNLEADED GASOLINE ONLY 91 Min. Pump Octane (R+M) / 2 NEVER ride as a 5PW-2415E-11 passenger. Passengers can cause a loss of control, WARNING resulting in SEVERE INJURY or DEATH. This unit contains high pressure nitrogen gas. Mishandling can cause explosion. 5FE-2151H-01 Read owner's manual for instructions.

  • Page 13: Safety Information

    EBU17431 SAFETY INFORMATION EBU29353 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 14 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 15 speed when climbing a hill. If you stall or roll Always use the size and type of tires specified in backwards, follow the special procedure for this manual. braking described in this manual. Dismount on Always maintain proper tire pressure as de- the uphill side or to a side if pointed straight up- scribed in this manual.
  • Page 16 Do not run engine outdoors where engine EWB00072 WARNING exhaust can be drawn into a building through openings such as windows and Avoid Carbon Monoxide Poisoning doors. All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can FOR MORE INFORMATION ABOUT ATV SAFE- cause headaches, dizziness, drowsiness, nau- TY, call the Consumer Products Safety Commis-...

  • Page 17: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 3 4 5 1. Front shock absorber assembly compression damping 1. Spark arrester force adjusting bolt (for fast compression damping) 2. Fuse 2. Front shock absorber assembly compression damping 3. Rear shock absorber assembly spring preload adjusting force adjusting screw (for slow compression damping) 3.

  • Page 18: Controls And Instruments

    EBU17712 Controls and instruments 1. Clutch lever 2. Parking brake lever 3. Handlebar switches 4. Fuel tank cap 5. Main switch 6. Front brake fluid reservoir 7. Throttle lever 8. Brake lever The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 19: Instrument And Control Functions

    EBU17725 INSTRUMENT AND CONTROL FUNCTIONS EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU29911 Main switch The positions of the main switch are as follows: “ ” (on) All electrical systems are supplied with power. The headlights and taillight come on when the light 1.

  • Page 20: Indicator Light And Warning Lights

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

  • Page 21: Handlebar Switches

    “ ” (on), or if the warning light This warning light comes on when the fuel level remains on, have a Yamaha dealer check the elec- drops below approximately 3.4 L (0.90 US gal, trical circuit.

  • Page 22: Throttle Lever

    to stop the engine in an emergency situation. The EBU18282 Throttle lever engine will not start or run when this switch is set Once the engine is running, pushing the throttle le- to “ ”. ver will increase the engine speed. EBU18101 Regulate the speed of the ATV by varying the Start switch “...

  • Page 23: Speed Limiter

    EBU18323 Speed limiter Your ATV is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 24: Brake Lever

    leased slowly for smooth clutch operation. (See page 6-1 for a description of the ignition circuit cut- off system.) 1. Brake lever 2. Locknut 3. Brake lever position adjusting bolt 4. Distance between brake lever and handlebar grip 1. Clutch lever EBU18432 EBU18423 Brake pedal...

  • Page 25: Parking Brake Lever

    1. Parking brake lever (locked position) 1. Brake pedal EBU18520 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a).

  • Page 26: Shift Pedal

    EWB00220 WARNING Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. Always be sure you have released the park- ing brake before you begin to ride.

  • Page 27: 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 28 Fuel reserve amount: rings, as well as to the exhaust system. 3.4 L (0.90 US gal, 0.75 Imp.gal) Your Yamaha engine has been designed to use 3. Wipe up any spilled fuel immediately. premium unleaded gasoline with a pump octane...

  • Page 29: Seat

    EBU18891 Seat To remove the seat Insert your hand between the rear of the seat and the rear fender, pull the seat lock lever upward and pull up the seat at the rear. 1. Projection 2. Seat holder EBU30050 Adjusting the front shock absorber as- semblies These shock absorber assemblies are equipped 1.
  • Page 30 would be advisable to check the number of clicks EWB02491 WARNING or turns of each damping force adjusting mecha- nism and to modify the specifications as neces- Suspension components become hot during sary. operation. Never touch the compression damping force adjusting bolt and screw, the rebound damping force adjusting screw or Spring preload the oil reservoir with your bare hand or skin...
  • Page 31 A special wrench can be obtained at a Yamaha dealer to make this adjustment. The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the higher the spring preload; the longer distance A is, the lower the spring preload.
  • Page 32 Rebound damping force Rebound damping setting: Turn the rebound damping force adjusting screw in Minimum (soft): direction (a) to increase the rebound damping 20 click(s) in direction (b)* force and thereby harden the damping, and in di- Standard: rection (b) to decrease the rebound damping force 12 click(s) in direction (b)* and thereby soften the damping.
  • Page 33 Compression damping force (for slow compres- sion damping) To increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting screw in di- rection (a). To decrease the compression damping force and thereby soften the compression damp- ing, turn the adjusting screw in direction (b).

  • Page 34: Adjusting The Rear Shock Absorber Assembly

    Do not dispose of a damaged or worn out Compression damping setting (for slow com- shock absorber assembly yourself. Take the pression damping): shock absorber assembly to a Yamaha deal- Minimum (soft): er for any service. 18 click(s) in direction (b)*...
  • Page 35 3. Loosen the clamp screw at the air filter case side. Spring preload 1. Remove the cowling. (See page 8-11 for YFZ45RB or 8-14 for YFZ45RSEB.) 2. Remove the clip from the hose holder, remove the bolt, and then move the blow-by gas chamber away from the vehicle.
  • Page 36 1. Clamp screw 1. Bolt 2. Collar 4. Remove the air filter case holding plate by re- 3. Air filter case holding plate moving the bolts and collars. 5. Remove the bolts, and then remove the air fil- ter case by disconnecting it from the air intake duct.
  • Page 37 7. Loosen the clamp screw at the throttle body side, and then disconnect the air intake duct from the throttle body. 1. Air filter case 2. Bolt 6. Disconnect the coupler. 1. Clamp screw 2. Air intake duct 8. Loosen the locknut. 9.
  • Page 38 Distance A = 253.5 mm (9.98 in) 1. Locknut 2. Spring preload adjusting nut 3. Special wrench A special wrench can be obtained at a Yamaha dealer to make this adjustment. The spring preload setting is determined by measuring distance A, shown in the illustration.
  • Page 39 15. Install the air filter case holding plate by install- Tightening torque: ing the bolts and collars, and then tighten the Locknut: bolts to the specified torque. 30 Nm (3.0 m·kgf, 22 ft·lbf) Tightening torque: 11. Connect the air intake duct to the throttle Air filter case holding plate bolt: body, and then tighten the clamp screw at the 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
  • Page 40 Compression damping force Remove the seat to make this adjustment. (See page 4-11.) If the adjustment is difficult, it may be necessary to remove panels A and C. (See page 8-9.) Compression damping force (for fast compression damping) To increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting bolt in direc- tion (a).
  • Page 41 Compression damping setting (for fast com- pression damping): Minimum (soft): 2 turn(s) out from the fully turned in posi- tion Standard: 1 turn(s) out from the fully turned in posi- tion Maximum (hard): Adjusting bolt fully turned in 1. Compression damping force adjusting screw (for slow Compression damping force (for slow compres- compression damping) sion damping)

  • Page 42: Handlebar Position

    EBU29401 Handlebar position The handlebar can be adjusted to one of four posi- tions to suit the rider’s preference. Have a Yamaha dealer adjust the position of the handlebar. 4-24...

  • Page 43: 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 44 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 5-4, 8-30, 8-32, 8-33 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.
  • Page 45 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate lever pivoting points if Brake and clutch levers 8-41 necessary. Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. Instruments, lights and • Check operation, and correct if necessary. switches...

  • Page 46: Fuel

    Check that there is no free play in the brake le- Test the brakes at slow speed after starting out to ver. If there is free play, have a Yamaha dealer make sure they are working properly. If the brakes check the brake system.

  • Page 47: Throttle Lever

    [EWB02541] Check the operation of the throttle lever. It must pressures to the following specifications: open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if Recommended tire pressure: necessary. Front 27.5 kPa (0.275 kgf/cm², 4.0 psi)
  • Page 48 EWB02551 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

  • Page 49: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are DUNLOP/KT352 Radial working properly. Correct if necessary. Size: AT21 x 7R10 Type: Tubeless Rear: Manufacturer/model: DUNLOP/KT357 Radial Size: AT20 x 10R9 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling,...

  • Page 50: Operation

    3. Shift the transmission into neutral. The neutral indicator light should come on, if it does not come on, have a Yamaha dealer check the EBU29952 Starting the engine electrical circuit.

  • Page 51: Shifting

    The clutch is disengaged with the transmission To shift into neutral, release the throttle lever, ap- in gear. However, it is recommended to shift into ply the clutch, and then repeatedly depress the neutral before starting the engine. shift pedal until it stops. When it stops, it will be in first gear.
  • Page 52 ECB00200 EBU20650 To decelerate NOTICE When slowing down or stopping, release the throt- Always close the throttle before shifting gears, tle and apply the brakes smoothly and evenly. As otherwise damage to the engine and drive train you slow down, shift to a lower gear. Be sure that may result.

  • Page 53: 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 54: Parking On A Slope

    Never park the ATV on hills that are too steep to walk up easily. 1. Bring the ATV to a stop by applying the front brake, shift into first gear, and then stop the engine. 2. With the front and rear brakes applied, apply the parking brake.

  • Page 55: Accessories And Loading

    An accessory which can shift position sories or offer other modifications for Yamaha or come off while you are riding could affect your vehicles. Yamaha is not in a position to test the ability to control the ATV. products that these aftermarket companies pro- Do not mount an accessory where it could inter- duce.
  • Page 56 If you are carrying cargo and towing a trailer, in- EBU20941 Loading clude the tongue weight in the maximum ATV EWB00820 load limit. WARNING Load cargo on the carriers as close to the center Never exceed the stated load capacity for this of the ATV as possible.
  • Page 57 EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 58: Riding Your Atv

    EBU21132 RIDING YOUR ATV...

  • Page 59: Getting To Know Your Atv

    Before you begin to ride, be sure you complete the certified training course offered by have read this Owner’s Manual completely and un- Yamaha. They should then regularly practice the derstand the operation of the controls. Pay partic- skills learned in the course and the operating tech-...
  • Page 60 niques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. 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.
  • Page 61 proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. [EWB01411] Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision.
  • Page 62 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 63 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 “MAXIMUM LOADING the maximum engine power available and de- LIMIT” below or vehicle labeling). creases the maximum speed of the ATV.
  • Page 64 All parts and accessories added to this ATV should be genuine Yamaha or equivalent components de- signed for use on this ATV and should be installed and used according to instructions. If you have...
  • Page 65 questions, consult an authorized ATV dealer. other hot parts. Check under the vehicle after op- WARNING! Operating this ATV with improper erating in areas where combustible materials may modifications may cause changes in handling have collected. Do not idle or park the vehicle in which in some situations could lead to an acci- long dry grass or other dry ground cover.

  • Page 66: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE ATVs on public streets, roads and highways. This ATV is designed for off-road use only. WARNING! Never operate this ATV on any pub- WARNING! Paved surfaces may seriously af- lic street, road or highway, even a dirt or gravel fect handling and control of the ATV, and may one.
  • Page 67 ful when operating on unfamiliar terrain. Al- ways be alert to changing terrain conditions when operating the ATV. [EWB01531] When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket Do not operate on rough, slippery, or loose terrain as a trailer hitch.
  • Page 68 Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.

  • Page 69: Turning Your Atv

    trol. NOTICE: Do not shift gears without To achieve maximum traction while riding off-road, [EWB02631] releasing the throttle. Damage to the engine or the two rear wheels turn together at the same drive train may occur. speed. Therefore, unless the wheel on the inside [ECB01071] Use this same procedure as you move into the of the turn is allowed to slip or lose some traction,...

  • Page 70: Climbing Uphill

    Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.
  • Page 71 Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
  • Page 72 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footrests and leaning forward over the handlebars. Whenever possible, ride straight up hills.
  • Page 73 If you start to roll backwards, DO NOT apply the rear brake, and apply the front brake gradually. The ATV could easily tip over backwards. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount the ATV im- mediately on the uphill side or to a side if pointed straight uphill.

  • Page 74: Riding Downhill

    RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- EWB01131 WARNING sible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the en- Going down a hill improperly could cause gine compression to do most of the braking for you.

  • Page 75: Crossing A Slope

    Avoid crossing the side of a steep hill. 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.

  • Page 76: Crossing Through Shallow Water

    than the depth specified in your Owner’s Man- ual, as tires may float, increasing the risk of an overturn. The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth.

  • Page 77: Riding Over Rough Terrain

    Test your brakes after leaving the water. If neces- Wash the ATV in fresh water if it has been operat- sary, apply them several times to let friction dry out ed in salt water or muddy conditions. the linings. Do not continue to ride your ATV with- out verifying that you have regained proper braking ability.

  • Page 78: Sliding And Skidding

    Riding over rough terrain should be done with cau- To reduce the tendency for the front wheels to slide tion. Look out for obstacles which could cause in loose or slippery conditions, positioning your damage to the ATV or could lead to an upset or ac- weight over the front wheels will sometimes help.

  • Page 79: What To Do If

    WHAT TO DO... If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footrest to the outside of the turn. Position your weight over the front wheels for better control.
  • Page 80 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 81: 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 82: Owner's Manual And Tool Kit

    If you do not have the tools or experience required manual by putting it in the plastic bag, then by plac- for a particular job, have a Yamaha dealer perform ing the bag in the document pouch. it for you.

  • Page 83: 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 84 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 85: 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 86 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 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Make sure that all nuts, bolts, and screws are √ √ √ √ √ 14 * Chassis fasteners properly tightened.
  • Page 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation. • Check throttle lever free play, and adjust if neces- √ √ √ √ √ Throttle lever sary.

  • Page 89: Removing And Installing The Cowling And Panels

    1. Panel C installed. EBU29538 Panel A (YFZ45RB) To remove the panel 1. Remove the seat. (See page 4-11.) 2. Remove the fuel tank cap by turning it coun- terclockwise. (See page 4-8.) NOTICE: Make sure that no foreign material enters the fuel tank.
  • Page 90 5. Install the fuel tank cap by turning it clockwise. To install the panel 1. Remove the fuel tank cap by turning it coun- terclockwise. 2. Place the panel in the original position, and then install the quick fasteners. NOTICE: When installing the panel, be sure not to pinch the cables or wires.
  • Page 91 Panels B and C (YFZ45RB) To remove a panel 1. Remove panel A. 2. Pull the panel off. 2. Install panel A. Cowling (YFZ45RB) To remove the cowling 1. Remove panels A, B and C. To install a panel 2. Remove the bolts, and then take the cowling 1.
  • Page 92 To install the cowling 1. Place the cowling in the original position, and then install the bolts. 2. Install panels C, B and A. EBU29595 Panel A (YFZ45RSEB) To remove the panel 1. Remove the seat. (See page 4-11.) 1. Bolt 2.
  • Page 93 5. Install the fuel tank cap by turning it clockwise. To install the panel 1. Remove the fuel tank cap by turning it coun- terclockwise. 2. Place the panel in the original position, and then install the quick fasteners. NOTICE: When installing the panel, be sure not to pinch the cables or wires.
  • Page 94 Panels B and C (YFZ45RSEB) To remove a panel 1. Remove panel A. 2. Pull the panel off. 2. Install panel A. Cowling (YFZ45RSEB) To remove the cowling 1. Remove panels A, B and C. To install a panel 2. Loosen the quick fasteners, and then take the 1.

  • Page 95: Checking The Spark Plug

    The spark plug is an important engine component, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- 1.

  • Page 96: Engine Oil And Oil Filter Element

    Specified spark plug: Tightening torque: NGK/CR8E Spark plug: 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Before installing the spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. If a torque wrench is not available when installing the spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight.
  • Page 97 To achieve the proper engine oil temperature for an accurate oil level reading, the engine must have first completely cooled down, and then warmed up again for several minutes to normal operating tem- perature. 3. Remove the engine oil tank filler cap, and wipe the engine oil dipstick off with a clean rag.
  • Page 98 When adding oil, be careful not to overfill the en- gine oil tank; the oil level rises faster starting from the half-level mark on the dipstick. 6. Insert the dipstick into the engine oil tank filler hole, and then tighten the engine oil tank filler cap.
  • Page 99 1. Engine oil tank drain bolt 1. Crankcase engine oil drain bolt 2. Gasket 2. Gasket 6. Remove the crankcase engine oil drain bolt and its gasket. Skip steps 7–10 if the oil filter element is not being replaced. 7. Remove the oil filter element cover by remov- ing the bolts.
  • Page 100 1. Oil filter element cover 1. Oil filter element 2. Bolt 2. O-ring 8. Remove the oil filter element and the O-rings. 9. Install a new oil filter element and new O- rings. Make sure that the O-rings are properly seated. 10.
  • Page 101 11. Install the crankcase engine oil drain bolt, the engine oil tank drain bolt and their new gasket, Be sure to wipe off spilled oil on any parts after the and then tighten the bolts to their specified engine and exhaust system have cooled down. torques.

  • Page 102: 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. Have a Yamaha dealer change the coolant. WARNING! Never attempt to remove the radiator cap when the engine is hot.

  • Page 103: Cleaning The Air Filter Element

    If dust or water collects in this hose, empty Yamaha dealer check the antifreeze con- the hose and clean the air filter element and air fil- tent of the coolant as soon as possible, ter case.
  • Page 104 1. Air filter case check hose 1. Air filter case cover 2. Air filter case cover holder 1. Place the ATV on a level surface. 4. Fully loosen the wing bolt. 2. Remove the seat. (See page 4-11.) 5. Remove the air filter element together with the 3.
  • Page 105 1. Air filter element 1. Sponge material 2. Washer 2. Air filter element frame 3. Wing bolt 8. Wash the sponge material gently but thor- 6. Remove the wing bolt and washer from the air oughly in solvent. WARNING! Always use filter element.
  • Page 106 10. Check the sponge material and replace it if damaged. 14. Install the washer onto the air filter element 11. Apply Yamaha foam air filter oil or other qual- frame, and then insert the wing bolt into the ity foam air filter oil to the sponge material.

  • Page 107: Cleaning The Spark Arrester

    17. Install the seat. The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar- eas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions.
  • Page 108 1. Tailpipe 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 109: Adjusting The Throttle Lever Free Play

    Tightening torque: Purging bolt: 27 Nm (2.7 m·kgf, 20 ft·lbf) EWB02380 WARNING Never run the engine in an enclosed area when purging the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monox- ide poisoning, possibly leading to death, and start a fire.

  • Page 110: Valve Clearance

    3. To increase the throttle lever free play, turn must be adjusted by a Yamaha dealer at the inter- the throttle lever free play adjusting bolt in di- vals specified in the periodic maintenance and lu- rection (a).
  • Page 111 If a brake pad has worn to the point that the wear indicator grooves have almost disap- that the wear indicator grooves have almost disap- peared, have a Yamaha dealer replace the brake peared, have a Yamaha dealer replace the brake pads as a set.

  • Page 112: Checking The Brake Fluid Level

    Rear brake EBU29501 Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid lev- el with the top of the reservoir level. Replenish the brake fluid if necessary. Front brake 1.

  • Page 113: Changing The Brake Fluid

    If the brake fluid level goes down suddenly, mance. have a Yamaha dealer check the cause before fur- Clean the filler cap before removing. Use ther riding. only DOT 4 brake fluid from a sealed contain-...

  • Page 114: Checking The Brake Pedal Height

    Cable length “A” should measure 47–51 mm 11.7 mm (0.46 in) below the top of the footrest as (1.85–2.01 in). Adjust the parking brake free play shown. If the brake pedal is not positioned as spec- as follows. ified, have a Yamaha dealer adjust it. 8-34...
  • Page 115 If the cable length cannot be adjusted to specifica- 2. Fully loosen the locknut and the adjusting bolt tion, consult a Yamaha dealer. at the rear brake caliper. 3. Slide the rubber cover back at the brake ca- 6.

  • Page 116: Brake Light Switches

    The brake light switch for the brake pedal can be that it does not turn together with the lock- adjusted as follows, but the front brake light switch nut. should be adjusted by a Yamaha dealer. [ECB00521] Turn the rear brake light switch adjusting nut while Tightening torque: holding the brake light switch in place.
  • Page 117 2. Fully turn the adjusting nut at the clutch lever scribed above or if the clutch does not operate cor- in direction (a) to loosen the clutch cable. rectly, have a Yamaha dealer check the internal 3. Slide the rubber cover back. clutch mechanism.

  • Page 118: Drive Chain Slack

    EBU26864 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. To check the drive chain slack 1. Place the ATV on a level surface. When checking and adjusting the drive chain slack, there should be no weight on the ATV and all tires must be touching the ground.
  • Page 119 1. Rear wheel axle pinch bolt 2. Rod 3. Drive chain tensioner 4. Hole 3 1 2 4 A rod can be obtained at a Yamaha dealer to make Tightening torque: this adjustment. Rear axle pinch bolt: 4. Shift the transmission into neutral.

  • Page 120: Lubricating The Drive Chain

    EBU24882 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. ECB00561 NOTICE The drive chain must be lubricated after wash-...

  • Page 121: Checking And Lubricating The Brake And Clutch Levers

    If a cable is damaged or does not move EBU24922 Checking and lubricating the brake and smoothly, have a Yamaha dealer check or replace clutch levers The operation of the brake and clutch levers Recommended lubricant: should be checked before each ride, and the lever Yamaha Chain and Cable Lube or engine oil pivots should be lubricated if necessary.

  • Page 122: Checking The Shift Pedal

    Checking and lubricating the brake in a wheel hub or if a wheel does not turn smoothly, pedal have a Yamaha dealer check the wheel hub bear- The operation of the brake pedal should be ings. checked before each ride, and the pedal pivot should be lubricated if necessary.

  • Page 123: Lubricating The Swingarm Pivots

    Lubricating the upper and lower arm The swingarm pivots must be lubricated by a pivots Yamaha dealer at the intervals specified in the pe- The upper and lower arm pivots must be lubricated riodic maintenance and lubrication chart. at the intervals specified in the periodic mainte- nance and lubrication chart.

  • Page 124: Lubricating The Steering Shaft

    2. Lower grease nipple 2. Lower grease nipple EBU25092 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. For parts equipped with a grease nipple, use a grease gun.

  • Page 125: Battery

    KEEP OUT OF REACH OF CHILDREN. EBU29189 Battery ECB00620 The battery is located under the seat. (See page NOTICE 4-11.) Never attempt to remove the battery cell seals, This model is equipped with a VRLA (Valve Regu- as this would permanently damage the battery. lated Lead Acid) battery.
  • Page 126 Always keep the battery charged. Storing a dis- To charge the battery charged battery can cause permanent battery Have a Yamaha dealer charge the battery as soon damage. as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more...

  • Page 127: Replacing The Fuse

    2. Connect the positive battery lead first, then EBU29961 Replacing the fuse connect the negative battery lead by installing their bolt. NOTICE: When installing the bat- tery, the main switch must be off, and the positive lead must be connected before the negative lead.

  • Page 128: Replacing A Headlight Bulb

    2. Remove the headlight bulb holder cover. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU30161 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 129 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the burnt-out bulb. 1. Do not touch the glass part of the bulb. 5. Install the headlight bulb holder by pushing it in and turning it clockwise. 1.

  • Page 130: Adjusting A Headlight Beam

    This model is equipped with an LED type of ECB00690 tail/brake light. NOTICE If the tail/brake light does not come on, have a It is advisable to have a Yamaha dealer make Yamaha dealer check it. this adjustment. EBU25651 To raise a headlight beam, turn the headlight beam Removing a wheel adjusting bolt in direction (a).

  • Page 131: Installing A Wheel

    1. Wheel nut 1. Arrow mark 3. Elevate the ATV and place a suitable stand 3. Lower the ATV to the ground. under the frame. 4. Tighten the wheel nuts to the specified 4. Remove the nuts from the wheel. torques.

  • Page 132: 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 133: 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 134 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 135: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25902 may cause water seepage and deteriora- Cleaning tion of wheel bearings, brakes, transmis- Frequent, thorough cleaning of your ATV will not sion seals and electrical devices. Many only enhance its appearance but will improve its expensive repair bills have resulted from general performance and extend the useful life of improper high-pressure detergent applica-...

  • Page 136: Storage

    3. Perform the following steps to protect the cyl- EBU27261 Storage inder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark Short-term plug. Always store your ATV in a cool, dry place and, if b. Pour a teaspoonful of engine oil into the necessary, protect it against dust with a porous spark plug bore.
  • Page 137 6. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 7. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an exces- sively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)].

  • Page 138: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Compression ratio: 11.40 : 1 Overall length: Starting system: 1795 mm (70.7 in) Electric starter Overall width: Lubrication system: 1240 mm (48.8 in) Dry sump Overall height: Engine oil: 1065 mm (41.9 in) Seat height: Recommended brand: 810 mm (31.9 in) YAMALUBE Wheelbase:...
  • Page 139 Clutch: Engine oil quantity: Without oil filter element replacement: Clutch type: 1.40 L (1.48 US qt, 1.23 Imp.qt) Wet, multiple-disc With oil filter element replacement: Transmission: 1.45 L (1.53 US qt, 1.28 Imp.qt) Primary reduction system: Cooling system: Spur gear Coolant reservoir capacity (up to the maximum level mark): Primary reduction ratio: 0.25 L (0.26 US qt, 0.22 Imp.qt)
  • Page 140 Front wheel: Trail: 21.0 mm (0.83 in) Wheel type: Front tire: Panel wheel Type: Rim size: Tubeless 10 x 5.5AT Size: Rear wheel: AT21 x 7R10 Wheel type: Manufacturer/model: Panel wheel DUNLOP/KT352 Radial Rim size: Rear tire: 9 x 8.0AT Front brake: Type: Tubeless...
  • Page 141 Rear suspension: Engine trouble warning light: Type: Fuse: Swingarm (link suspension) Spring/shock absorber type: Fuse: Coil spring/gas-oil damper 20.0 A Wheel travel: 280 mm (11.0 in) Electrical system: Ignition system: Charging system: AC magneto Battery: Model: YTZ7S Voltage, capacity: 12 V, 6.0 Ah Headlight: Bulb type: Krypton bulb...

  • Page 142: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 143 Model label ment Canada. The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 144 1. Vehicle Emission Control Information label 11-3...

  • Page 145: 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 146: 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 147: 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 148 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 149: 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 150 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 151 INDEX Drive chain, lubricating ..........8-40 Drive chain slack ............8-38 Accessories and loading ..........6-6 Air filter element, cleaning ..........8-23 Engine break-in .............. 6-4 Engine oil ............... 5-4 Battery ................8-45 Engine oil and oil filter element ........8-16 Brake and clutch levers, checking and lubricating ..
  • Page 152 Steering shaft, lubricating ..........8-44 Storage ................9-2 Main switch ..............4-1 Suspension, lubricating the upper and Maintenance and lubrication chart ......... 8-5 lower arm pivots ............8-43 Maintenance chart, emission control system ....8-3 Swingarm pivots, lubricating ........8-43 Maintenance record .............
  • Page 153 EBU30390 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect.
  • Page 154 EBU26141 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER ALWAYS operate: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough...

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