Yamaha GRIZZLY 700 FI YFM7FGPW Owner's Manual
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Yamaha GRIZZLY 700 FI YFM7FGPW Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM7FGPW
3B4-28199-60

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Summary of Contents for Yamaha GRIZZLY 700 FI YFM7FGPW

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM7FGPW 3B4-28199-60...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2006.05-1.4×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 OWNER’S MANUAL YFM7FGPW 3B4-28199-60-E0...

  • Page 4: Ec Declaration Of Conformity

    EBU27850 EC Declaration of Conformity conforming to Directive 98/37/EC YAMAHA MOTOR CO., LTD. (Name of supplier) 2500 Shingai, Iwata, Shizuoka, Japan declare in sole responsibility, that the product YFM700FWAD (JY4AM09W060000001~) (Make, model) to which this declaration applies, conforms to the essential...
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 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 7 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Storage compartments ......4-18 Front carrier ..........4-21 LOCATION OF THE WARNING AND Rear carrier ..........4-21 SPECIFICATION LABELS ......2-1 Adjusting the front and rear shock absorber assemblies .......4-21 DESCRIPTION ..........3-1 Auxiliary DC jack ........4-22 Left view ............
  • Page 9 Operating the drive select lever and Periodic maintenance and lubrication driving in reverse ........6-2 chart ............8-3 Engine break-in .......... 6-4 Removing and installing panels ....8-8 Parking ............6-5 Checking the spark plug ......8-20 Parking on a slope ........6-5 Engine oil and oil filter cartridge ....8-22 Accessories and loading ......
  • Page 10 Checking and lubricating the front and SPECIFICATIONS ........10-1 rear brake levers ........8-52 Checking and lubricating the brake CONSUMER INFORMATION.......11-1 pedal ............8-53 Identification numbers .......11-1 Checking the wheel bearings ....8-53 Lubricating the drive shaft universal joint ............8-53 Checking the stabilizer bushes ....

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION EBU27250 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 12 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 13 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 14 nition such as the pilot lights of water heat- ers and clothes dryers. Gasoline can catch fire and you could be burned. When transporting the ATV in another vehi- cle, be sure it is kept upright. Otherwise, fuel may leak out of the fuel tank. Gasoline is poisonous.

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. For Europe and Oceania...
  • Page 17 For Europe...
  • Page 18 For Europe...
  • Page 19 For Europe...
  • Page 20 For Oceania...
  • Page 21 For Oceania...

  • Page 22: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 1. Rear shock absorber assembly spring preload adjusting ring 2. Battery 2. Rear storage compartment and tool kit 3. Fuses 3. Fuel tank cap cover 4. Air filter case 4.

  • Page 23: Controls And Instruments

    EBU17712 NOTE: Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Drive select lever 2. Rear brake lever 3. Handlebar switches 4. Horn switch 5. Rear brake fluid reservoir 6. Multifunction meter unit 7.

  • Page 24: Instrument And Control Functions

    EBU17730 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

  • Page 25: Indicator Lights And Warning Lights

    3. High-range indicator light “H” checked by turning the key to “ON”. If the light does 4. Neutral indicator light “N” not come on, have a Yamaha dealer inspect the 5. Reverse indicator light “R” electrical circuit. 6. Park indicator light “P”...
  • Page 26 Continuous use while checked by turning the key to “ON”. If the warning the warning light is on may cause damage to light does not come on, have a Yamaha dealer the engine. check the electrical circuit.
  • Page 27 EBU18001 NOTE: On-Command differential gear lock indicator Due to the synchronizing mechanism in the dif- light “DIFF. LOCK” ferential gear case, the four-wheel-drive indica- This indicator light and the On-Command differen- tor may not come on until the ATV starts moving. tial gear lock indicator in the display come on when When the On-Command differential gear lock the On-Command differential gear lock switch is...

  • Page 28: Multifunction Display

    EBU27291 a clock Multifunction display an hour meter (which shows the total time the key has been turned to “ON”) a fuel meter a self-diagnosis device Odometer and tripmeter modes Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the trip- meter modes “A”...
  • Page 29 1. Set the display to the clock mode. display segments and fuel level warning indicator 2. Push the “SELECT” button and “RESET” but- will start flashing. If this occurs, have a Yamaha ton together for at least three seconds. dealer check the electrical circuit.

  • Page 30: Handlebar Switches

    If the multifunction display indicates such an error EBU18080 code, note the code number, and then have a Engine stop switch “ ” Yamaha dealer check the vehicle. Set this switch to “ ” before starting the engine. ECB00810 The engine stop switch controls the ignition and CAUTION: stops the engine when it is running.
  • Page 31 EBU18100 EBU18190 Start switch “ ” Override switch “OVERRIDE” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18151 Light switch “ /OFF” Set this switch to “ ”...
  • Page 32 In To change from two-wheel drive to four-wheel this case, take the ATV to a Yamaha dealer at the drive, stop the ATV and push the switch in to the first opportunity.
  • Page 33 EBU18252 On-Command differential gear lock switch “4WD”/“LOCK” 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. “4WD” (four-wheel drive): Power is supplied to the rear and front wheels.
  • Page 34 To lock the differential gear in four-wheel drive, make sure the On-Command four-wheel-drive switch is pushed in to the “4WD” position. 1. On-Command differential gear lock switch “4WD”/“LOCK” To release the differential gear lock, stop the ATV and push the switch to the “4WD” position. 1.

  • Page 35: Throttle Lever

    pectedly. This could distract the operator and Riding before the differential gear lock is proper- increase the risk of losing control and causing ly engaged (e.g., when the indicator and indica- an accident. tor light are flashing) will cause the engine speed to be limited until engagement is complete.

  • Page 36: Speed Limiter

    If the throttle does not work smoothly, check for the cause. Correct the problem be- fore riding the ATV or consult a Yamaha dealer. 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in)

  • Page 37: Front Brake Lever

    3. Tighten the locknut. EWB00240 WARNING Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be dam- aged.

  • Page 38: Drive Select Lever

    EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-2 for the drive select lever operation. 1.

  • Page 39: Fuel

    To install the fuel tank cap Install the fuel tank cap by turning it clockwise until a click is heard, and then close the fuel tank cap cover. EBU18750 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.

  • Page 40: Seat

    Be careful not to spill fuel, especially on the Recommended fuel: engine or exhaust pipe which can cause a UNLEADED GASOLINE ONLY fire and severe injury. Wipe up any spilled For Europe: Regular unleaded gasoline only fuel immediately. with a research octane number of 91 or high- Do not refuel right after the engine has been running and is still very hot.

  • Page 41: Storage Compartments

    To install the seat The front storage compartment is located at the Insert the projections on the front of the seat into front right side of the ATV. To access the storage the seat holders and push down on the seat at the compartment, remove the storage compartment rear.
  • Page 42 1. Front storage compartment 1. Rear storage compartment cover The rear storage compartment is located under the seat. (See page 4-17.) To access the storage com- partment, remove the storage compartment cover. 1. Rear storage compartment 4-19...
  • Page 43 When storing any documents in the storage com- partments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartments. ECB00830 CAUTION: Do not store metal or sharply edged objects,...

  • Page 44: Front Carrier

    2. Position indicator EBU19140 Adjusting the front and rear shock ab- NOTE: A special wrench can be obtained at a Yamaha sorber assemblies dealer to make this adjustment. The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions.

  • Page 45: Auxiliary Dc Jack

    EWB00400 WARNING Always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. EBU19180 Auxiliary DC jack The auxiliary DC jack is located at the front right 1.
  • Page 46 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 47: 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 48 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check pedal free play, and adjust if necessary. 5-4, 8-44, 8-46, 8-48, Rear brake • Check brake pads for wear, and replace if necessary.

  • Page 49: Fuel

    EBU19540 EBU19600 Fuel Differential gear oil Make sure that there is sufficient fuel in the tank. Make sure that the differential gear oil is at the (See page 4-16.) specified level. Add oil as necessary. (See page EWB00520 8-28.) WARNING EBU19630 Do not overfill the fuel tank.

  • Page 50: Front And Rear Brakes

    Always check the brakes at the start of every plied. If not, have a Yamaha dealer check the ride. Do not ride the ATV if you find any prob- brake system.

  • Page 51: Throttle Lever

    Throttle lever Tubeless Check the operation of the throttle lever. It must Rear: open smoothly and spring back to the idle position Manufacturer/model: when released. Have a Yamaha dealer correct if CHENG SHIN/C828-4P (AUS)(NZL) necessary. DUNLOP/KT425 (EUR) Size: EBU19791 AT25 x 10-12...

  • Page 52: Measuring The Tire Pressure

    Minimum tire pressure: Front: 32.0 kPa (4.6 psi) (0.320 kgf/cm²) Rear: 27.0 kPa (3.9 psi) (0.270 kgf/cm²) • Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (36 psi) (2.5 kgf/cm²) Rear: 250 kPa (36 psi) (2.5 kgf/cm²) 1.

  • Page 53: Tire Wear Limit

    Recommended pressure: Front 35.0 kPa (5.0 psi) (0.350 kgf/cm²) Rear 30.0 kPa (4.3 psi) (0.300 kgf/cm²) Minimum: Front 32.0 kPa (4.6 psi) (0.320 kgf/cm²) Rear 27.0 kPa (3.9 psi) (0.270 kgf/cm²) Maximum: 1. Tire wear limit Front 38.0 kPa (5.5 psi) (0.380 kgf/cm²) EBU19840 Chassis fasteners Rear...

  • Page 54: Operation

    The coolant temperature warning light and en- accident or injury. If there is a control or func- gine trouble warning light should come on, tion you do not understand, ask your Yamaha then go off. dealer. The EPS warning light should come on, then go off when the engine is started.

  • Page 55: Operating The Drive Select Lever And Driving In Reverse

    ECB00160 NOTE: CAUTION: This model is equipped with an ignition circuit cut- For maximum engine life, always warm the en- off system. The engine can be started under the gine up before starting off. Never accelerate following conditions: hard when the engine is cold! The drive select lever is in the neutral or park po- sition.
  • Page 56 Shifting: Neutral to Reverse and Reverse to NOTE: Park Make sure that the drive select lever is completely shifted into position. NOTE: The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal. 1.

  • Page 57: Engine Break-In

    If the indicator light does not cessive load on it for the first 20 hours. The various come on, have a Yamaha dealer check the elec- parts in the engine wear and polish themselves to trical circuit.

  • Page 58: Parking

    If any engine trouble should occur during the steep you could not walk up them easily. engine break-in period, immediately have a 1. Bring the ATV to a stop by applying the Yamaha dealer check the ATV. brakes. 2. Stop the engine. EBU27321 3.

  • Page 59: Accessories And Loading

    Keep the may also be available on the market. However, following points in mind: it is not possible for Yamaha to test all non- Never exceed the weight limits shown. An over- Yamaha accessories, nor control over their qual-...
  • Page 60 the weight on the hitch. If you are carrying cargo MAXIMUM LOADING LIMIT and towing a trailer, include the tongue weight in ATV loading limit (total weight of rider, cargo, the maximum ATV load limit. accessories, and tongue): Load cargo on the carriers as close to the center 220.0 kg (485 lb) of the ATV as possible.
  • Page 61 EWB00820 WARNING Never exceed the stated load capacity for this ATV. Overloading this ATV or carrying or tow- ing cargo improperly could cause changes in ATV handling which could lead to an accident. Cargo should be properly distributed and se- curely attached.

  • Page 62: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 63: Getting To Know Your Atv

    EBU27411 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV Beginners should get training from a certified in- This ATV is mainly for utility use, but may also be structor. used for recreation. This section, Riding your ATV, Become familiar with this ATV at slow speeds first, provides general ATV riding instructions for recre- even if you are an experienced operator.
  • Page 64 Not recommended for children under 16 years This ATV is designed to carry operator and car- of age. go only – passengers prohibited. EWB01390 EWB01400 WARNING WARNING A child under 16 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 90 cc.
  • Page 65 Apparel Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet...
  • Page 66 EWB01410 WARNING Never operate this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 67 in the Owner’s Manual. Failure to inspect the Speed limiter ATV before operating or failure to properly For riders less experienced with this model, the maintain the ATV increases the possibility of throttle lever housing is equipped with a speed lim- an accident or equipment damage.
  • Page 68 Loading and accessories EWB01460 WARNING Use extra caution when riding the ATV with addi- tional loads, such as accessories or cargo. The Never exceed the stated load capacity for ATV’s handling may be adversely affected. Re- this ATV. duce your speed when adding additional loads. Cargo should be properly distributed and se- curely attached.
  • Page 69 All parts and tact with the rear wheels, which could injure accessories added to this ATV should be gen- you or cause an accident. uine Yamaha or equivalent components de- signed for use on this ATV and should be...

  • Page 70: Be Careful Where You Ride

    installed and used according to instructions. Improper installation of accessories or modifi- cation of this ATV may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized ATV dealer. Exhaust system The exhaust system on the ATV is very hot during and following operation.
  • Page 71 EWB01520 WARNING Never operate this ATV on any paved street, paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. While riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles.
  • Page 72 EWB01530 ATV on such terrain. Failure to use extra care WARNING when operating on excessively rough, slippery or loose terrain could cause loss of traction or Go slowly and be extra careful when operating ATV control, which could result in an accident, on unfamiliar terrain.
  • Page 73 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice EWB01550 control of the throttle, brakes, shifting procedures, WARNING and turning techniques in this area before trying Always mount a caution flag on the ATV to more difficult terrain.

  • Page 74: Turning Your Atv

    With the engine idling, shift the drive select lever wheels also turn together at the same speed. into the low-range position or the high-range posi- Therefore, unless the wheel on the inside of the tion. Apply the throttle slowly and smoothly. The turn is allowed to slip or lose some traction, the centrifugal clutch will engage and you will start to ATV will resist turning.

  • Page 75: 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 76 EWB01580 Never go over the top of any hill at high WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never operate the ATV on hills too steep for the of the hill. ATV or for your abilities.
  • Page 77 EWB01600 WARNING Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.

  • Page 78: Riding Downhill

    could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediate- ly on the uphill side. EWB01801 WARNING Use the proper gear and maintain a steady speed when climbing a hill.

  • Page 79: Crossing A Slope

    When this ATV is in 4WD or 4WD-LOCK, all Avoid going down a hill at an angle that wheels (front and rear) are interconnected by the would cause the ATV to lean sharply to one drive train. This means that applying either the side.

  • Page 80: Crossing Through Shallow Water

    to cross a sloping surface. Avoid slopes with slip- Shift your weight to the uphill side of the pery surfaces or rough terrain that may upset your ATV. balance. As you travel across a slope, lean your body in the uphill direction.
  • Page 81 EWB01640 Test your brakes after leaving the water. Do not WARNING continue to ride your ATV without verifying that you have regained proper braking ability. Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual.
  • Page 82 1. Air filter case check hose 1. Storage compartment drain plug 1. Air filter case check hose 1. Storage compartment drain plug 7-21...

  • Page 83: Riding Over Rough Terrain

    you go over obstacles, always follow proper procedures as described in the Owner’s Manu- SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident.

  • Page 84: What To Do If

    If the rear wheels of your ATV start to slide side- EWB01661 WARNING ways, control can usually be regained (if there is room to do so) by steering in the direction of the Learn to safely control skidding or sliding by slide.
  • Page 85 If your ATV starts to slide sideways: BRAKES FOR PROPER OPERATION when Steer in the direction of the slide if you have the you come out of the water. Do not continue to room. Applying the brakes or accelerating is not ride your ATV until you have regained adequate recommended until you have corrected the braking ability.

  • Page 86: Periodic Maintenance And Minor Repair

    EBU21653 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21670 otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with Safety is an obligation of the owner. Periodic in- maintenance work. spection, adjustment and lubrication will keep your...
  • Page 87 NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING Never modify this ATV through improper in-...

  • Page 88: Periodic 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 89 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours • Check operation and correct if necessary. • Check brake pedal free play and adjust if neces- √ √...
  • Page 90 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours • Make sure that all nuts, bolts, and screws are √ √ √ √ √ Chassis fasteners properly tightened. Shock absorber as- •...
  • Page 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours • Change. √ √ Differential gear oil • Check ATV for oil leakage, and correct if neces- sary. •...
  • Page 92 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours • Check operation and correct if necessary. √ √ √ √ √ Lights and switches • Adjust headlight beams. EBU23070 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 93: Removing And Installing Panels

    EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel E 2.
  • Page 94 Panel B To remove the panel 1. Remove panel A. 2. Remove the front carrier by removing the bolts. 1. Panel A To install the panel Place the panel in the original position. 1. Carrier bolt (under the fenders)
  • Page 95 1. Carrier bolt (top) 1. Front carrier stay bolt 3. Remove the front carrier stays by removing 4. Remove the quick fastener screws, and then the bolts. pull the panel upward to remove it. 1. Front carrier stay 8-10...
  • Page 96 1. Panel B 2. Install the front carrier stays by installing the 2. Quick fastener screw bolts and tightening them to the specified torque. To install the panel 1. Place the panel in the original position, and Tightening torque: then install the quick fastener screws. Front carrier stay bolt: 26 Nm (2.6 m·kgf, 19 ft·lbf) 3.
  • Page 97 Tightening torques: Carrier bolt (top): 26 Nm (2.6 m·kgf, 19 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 4. Install panel A. Panel C To remove the panel 1. Remove the seat. (See page 4-17.) 1. Panel C 2.
  • Page 98 1. Panel D 2. Install panel A. 2. Quick fastener screw 3. Install the seat. Panels D and E To remove one of the panels 1. Remove panel C. 2. Remove the quick fastener screw and bolt, and then pull the panel upward as shown to remove it.
  • Page 99 To install one of the panels 1. Place the panel in the original position, and then install the bolt and quick fastener screw. 1. Panel E 2. Quick fastener screw 1. Bolt 2. Install panel C. 8-14...
  • Page 100 Panel F To remove the panel Pull outward on the areas shown. Panel G To remove the panel Remove the nut, bolts, and quick fastener, and 1. Panel F then pull the panel downward while pushing the tab. To install the panel Place the panel in the original position.
  • Page 101 1. Panel G Panel H 2. Nut 3. Bolt To remove the panel 4. Quick fastener Remove the nut, bolts, and quick fasteners, and 5. Tab then pull the panel downward while pushing the To install the panel tab. Place the panel in the original position, and then in- stall the bolts, nut, and quick fastener.
  • Page 102 1. Panel H Panel I 2. Nut 3. Bolt To remove the panel 4. Quick fastener 1. Remove the seat. (See page 4-17.) 5. Tab 2. Remove the rear carrier by removing the To install the panel bolts. Place the panel in the original position, and then in- stall the bolts, nut, and quick fasteners.
  • Page 103 1. Carrier bolt (under the fenders) 1. Carrier bolt (lower) 3. Remove the quick fasteners, and then push inward on the areas shown. 1. Carrier bolt (upper) 8-18...
  • Page 104 1. Panel I 2. Install the rear carrier by installing the bolts 2. Quick fastener and tightening them to the specified torques. To install the panel Tightening torques: 1. Place the panel in the original position, and Carrier bolt (upper): then install the quick fasteners.

  • Page 105: Checking The Spark Plug

    NOTE: If the spark plug shows a distinctly different color, 1. Spark plug cap the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-20...
  • Page 106 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/CR8E To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

  • Page 107: Engine Oil And Oil Filter Cartridge

    4. Remove the dipstick, and then wipe it off with NOTE: a clean rag. 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.
  • Page 108 ECB00850 CAUTION: Be sure the engine oil is at the correct level, otherwise engine damage may result. To change the engine oil (with or without oil fil- ter cartridge replacement) 1. Place the ATV on a level surface. 2. Remove panel F. (See page 8-8.) 3.
  • Page 109 1. Oil filter cartridge 2. Oil filter wrench NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 7. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
  • Page 110 11. Add the specified amount of the recommend- ed engine oil, and then insert the dipstick com- pletely into the oil filler hole. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.00 L (2.11 US qt) (1.76 Imp.qt) With oil filter cartridge replacement: 2.10 L (2.22 US qt) (1.85 Imp.qt) 1.

  • Page 111: 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 112 3. Remove the final gear oil filler bolt, final gear oil level check bolt, and the final gear oil drain bolt to drain the oil from the final gear case. 1. Final gear oil filler bolt 4. Install the oil level check bolt and oil filler bolt, and then tighten them to the specified torques.

  • Page 113: Differential Gear Oil

    1. Final gear oil leakage before each ride. If any leakage is found, 2. Final gear oil level check bolt have a Yamaha dealer check and repair the ATV. 3. Correct oil level In addition, the differential gear oil level must be...
  • Page 114 2. Remove the differential gear oil filler bolt, and Tightening torque: then check the oil level in the differential gear Differential gear oil filler bolt: case. 23 Nm (2.3 m·kgf, 17 ft·lbf) To change the differential gear oil 1. Place the ATV on a level surface. 2.

  • Page 115: Coolant

    ECB00410 Tightening torque: CAUTION: Differential gear oil drain bolt: Be sure no foreign material enters the differen- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) tial gear case. 5. Add the recommended differential gear oil to 6. Install the oil filler bolt, and then tighten it to the the brim of the filler hole as shown.
  • Page 116 4. Remove the reservoir cap, add coolant or dis- NOTE: tilled water to the maximum level mark, install The coolant level must be checked on a cold en- the reservoir cap, and then install the panel. gine since the level varies with engine tempera- ture.
  • Page 117 If water has been added to the coolant, have 1. Place the ATV on a level surface. a Yamaha dealer check the antifreeze con- 2. Remove panels D and F. (See page 8-8.) tent of the coolant as soon as possible, oth- 3.
  • Page 118 1. Coolant drain bolt 1. Radiator cap 6. Remove the coolant reservoir cap. 7. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the cool- ant reservoir. 1. Trough 4. Remove panel B. (See page 8-8.) 5.
  • Page 119 12. Pour the recommended coolant into the reser- voir to the maximum level mark, and then in- stall the reservoir cap. 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.
  • Page 120 If water has been added to the coolant, have Tightening torque: a Yamaha dealer check the antifreeze con- Water pump air bleed bolt: tent of the coolant as soon as possible, oth- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) erwise the effectiveness of the coolant will be reduced.

  • Page 121: Cleaning The Air Filter Element

    23. Start the engine, and then check for coolant leakage. NOTE: If any leakage is found, have a Yamaha dealer check the cooling system. 24. Install the V-belt cooling duct, and then tighten 1. Cylinder head air bleed bolt the clamp screw.
  • Page 122 the panels.) Check the hoses periodically and, if dust or water collects in them, empty them and clean the air filter element and air filter case. 1. Air filter case check hose 1. Remove panel C. (See page 8-8.) 2. Remove the air filter case cover by unhooking the holders.
  • Page 123 1. Air filter case holder 1. Sponge material 2. Air filter case cover 2. Air filter mesh 3. Remove the sponge material and the mesh 4. Clean the mesh with solvent, and then wipe from the air filter case. the solvent off. 5.
  • Page 124 7. Check the sponge material and replace it if damaged. 8. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. NOTE: The sponge material should be wet but not drip- ping.

  • Page 125: Cleaning The Spark Arrester

    ECB00760 CAUTION: Make sure that the air filter element is prop- erly seated in the air filter case. Never operate the engine with the air filter el- ement removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage.
  • Page 126 1. Tailpipe 1. Purging bolt 2. Spark arrester 7. Start the engine and rev it up approximately 3. Gasket twenty times while momentarily creating ex- 4. Install the gasket, and then insert the tailpipe haust system back pressure by blocking the into the muffler and align the bolt holes.

  • Page 127: V-Belt Case Drain Plug

    A diagnostic tachometer is needed to make this If water drains from the V-belt case after removing adjustment. the plug, have a Yamaha dealer check the ATV as 1. Start the engine and warm it up. the water may affect other engine parts.

  • Page 128: Adjusting The Throttle Cable Free Play

    2. Remove panel C. (See page 8-8.) 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 4. Check the engine idling speed and, if neces- adjustment.

  • Page 129: Valve Clearance

    2. To increase the throttle cable free play, turn must be adjusted by a Yamaha dealer at the inter- the adjusting bolt in direction (a). To decrease vals specified in the periodic maintenance and lu- the throttle cable free play, turn the adjusting brication chart.

  • Page 130: Checking The Rear Brake Hose Protectors

    Each brake hose protector is provided with a wear indicator. If a protector wears to the point that its indicator be- comes visible, have a Yamaha dealer replace the protector. 8-45...

  • Page 131: Checking The Brake Fluid Level

    Before riding, check that the brake fluid is above NOTE: the minimum level mark and replenish if neces- The wheels need to be removed to check the sary. A low brake fluid level may indicate worn brake hose protectors. (See page 8-62.) brake pads and/or brake system leakage.

  • Page 132: Changing The Brake Fluid

    EBU24290 Changing the brake fluid Observe these precautions: Have a Yamaha dealer change the brake fluid at When checking the fluid level, make sure that the intervals specified in the NOTE after the peri- the top of the brake fluid reservoir is level.

  • Page 133: Checking The Front And Rear Brake Lever Free Play

    Each brake le- ver should have a free play of zero mm (zero in) as shown. If the free play is incorrect, have a Yamaha dealer check the brake system. Front brake 1.

  • Page 134: Adjusting The Brake Pedal Free Play And Checking The Brake Pedal Position

    Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU27780 Adjusting the brake pedal free play and checking the brake pedal position The brake pedal free play must be adjusted and brake pedal position must be checked and, if nec- essary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 135 The top of the brake pedal should be positioned 56.7 mm (2.23 in) above the top of the footrest. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 1. Locknut 2. Brake pedal free play adjusting nut 4.

  • Page 136: Axle Boots

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil 1.

  • Page 137: Checking And Lubricating The Front And Rear Brake Levers

    EWB02130 Front brake lever WARNING Inspect cables frequently and replace if dam- aged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could re- strict the operation of controls and lead to an accident or injury.

  • Page 138: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel bearings. NOTE: To access the brake pedal pivot, remove panel H.

  • Page 139: Lubricating The Upper And Lower Arm Pivots

    EBU25040 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Recommended lubricant: Lithium-soap-based grease EBU25050 Lubricating the knuckle pivots 1. Grease nipple The knuckle pivots must be lubricated at the inter- vals specified in the periodic maintenance and lu- EBU25080...

  • Page 140: Battery

    There is no need to check the electrolyte or to add To charge the battery distilled water. Check and, if necessary, tighten the Have a Yamaha dealer charge the battery as soon battery lead connections. as possible if it seems to have discharged. Keep in...

  • Page 141: Replacing A Fuse

    1. Place the battery in its compartment. access to a constant-voltage battery charg- 2. Make sure to properly connect the battery er, have a Yamaha dealer charge your bat- leads to the battery terminals. tery. EBU27750 Replacing a fuse 1. Positive battery terminal 2.
  • Page 142 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. 1. Ignition fuse 2. Headlight fuse 3. Four-wheel-drive motor fuse 4.

  • Page 143: Replacing A Headlight Bulb

    10.0 A circuits to check if the devices operate. Signaling system fuse: 4. If the fuse immediately blows again, have a 5.0 A Yamaha dealer check the electrical system. Auxiliary DC jack fuse: EBU27440 15.0 A Replacing a headlight bulb Radiator fan fuse: If a headlight bulb burns out, replace it as follows.
  • Page 144 1. Cover at the rear of the headlight 1. Headlight coupler 2. Remove the headlight bulb cover. 4. Unhook the headlight bulb holder, and then remove the defective bulb. 1. Headlight bulb cover 3. Disconnect the headlight coupler. 8-59...
  • Page 145 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. 2. Headlight bulb ECB00650 CAUTION: EWB02220 WARNING Do not touch the glass part of the headlight A headlight bulb is hot when it is on and imme- bulb to keep it free from oil, otherwise the diately after it is turned off.

  • Page 146: Adjusting A Headlight Beam

    9. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make 1. Headlight beam adjusting screw this adjustment. EBU25640 Replacing the tail/brake light bulb To raise a headlight beam, turn the adjusting screw in direction (a).

  • Page 147: Removing A Wheel

    4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the panel. EBU25650 Removing a wheel 1.

  • Page 148: Installing A Wheel

    EBU25700 Installing a wheel 1. Install the wheel and the nuts. NOTE: The arrow mark on the tire must point toward the rotating direction of the wheel. Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel.

  • Page 149: 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 150: 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 151 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 152: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25880 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 153: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the brakes after washing. Apply the brakes several 2.
  • Page 154 e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. 4. Lubricate all control cables and the pivoting points of all levers and pedals. 5. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground.

  • Page 155: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Cylinder arrangement: Forward-inclined single cylinder Overall length: Displacement: 2065 mm (81.3 in) 686.0 cm³ Overall width: Bore × stroke: 1180 mm (46.5 in) 102.0 × 84.0 mm (4.02 × 3.31 in) Overall height: Compression ratio: 1240 mm (48.8 in) 9.20 :1 Seat height: Starting system:...
  • Page 156 Engine oil: Differential gear oil: Type: Type: SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 SAE80 API GL-4 Hypoid gear oil or SAE20W40 or SAE20W50 Quantity: 0.22 L (0.23 US qt) (0.19 Imp.qt) Cooling system: -20˚ -10˚ 0˚ 20˚ 30˚ 40˚ 50˚C 10˚...
  • Page 157 Clutch: Size: AT25 x 8-12 Clutch type: Manufacturer/model: Wet, centrifugal automatic CHENG SHIN/C828-4P (AUS)(NZL) Transmission: DUNLOP/KT421 (EUR) Primary reduction system: Rear tire: V-belt Type: Secondary reduction system: Tubeless Shaft drive Size: Secondary reduction ratio: 41/21 × 24/18 × 33/9 (9.544) AT25 x 10-12 Manufacturer/model: Transmission type:...
  • Page 158 Rear: Wheel travel: 33.0 kPa (4.8 psi) (0.330 kgf/cm²) 180 mm (7.1 in) Front wheel: Rear suspension: Wheel type: Type: Panel wheel Double wishbone Rim size: Spring/shock absorber type: 12 x 6.0AT Coil spring/oil damper Rear wheel: Wheel travel: 230 mm (9.1 in) Wheel type: Electrical system: Panel wheel...
  • Page 159 Reverse indicator light: Auxiliary DC jack fuse: 15.0 A Coolant temperature warning light: Four-wheel-drive motor fuse: 10.0 A Engine trouble warning light: Radiator fan fuse: 15.0 A EPS warning light: Park indicator light: On-Command four-wheel-drive/differential gear lock indicator: High-range indicator light: Low-range indicator light: Differential gear lock indicator light: Fuses:...

  • Page 160: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 161 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 162 1. Model label 11-3...
  • Page 163 INDEX Differential gear oil ..........5-3, 8-28 Drive select lever ............4-15 Accessories and loading ..........6-6 Drive select lever and driving in reverse ......6-2 Accessories, auxiliary jack ........... 4-22 Drive select lever safety system cable, adjusting ..8-44 Air filter element, cleaning ..........
  • Page 164 Indicator lights and warning lights ........4-2 Instruments, lights and switches ........5-7 Safety information ............1-1 Seat ................4-17 Key identification number ..........11-1 Shock absorber assemblies, adjusting the front and Knuckle pivots, lubricating ..........8-54 rear ................4-21 Knuckle shafts, lubricating ...........
  • Page 165 Wheel, installing ............8-63 Wheel, removing ............8-62...
  • Page 166 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.05-1.4×1 CR...

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