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Yamaha WOLVERINE 450 YFM45FXY Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
OWNER'S MANUAL
YFM45FXY
3C2-F8199-63

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Summary of Contents for Yamaha WOLVERINE 450 YFM45FXY

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM45FXY 3C2-F8199-63...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2008.05-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45FXY 3C2-F8199-63-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 98 / 37 /EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM450FAS (5Y4AJ21W080503201~)
  • 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 EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 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 Starter (choke) ..........4-12 Seat ............4-12 LOCATION OF THE WARNING AND Storage compartment .......4-13 SPECIFICATION LABELS ......2-1 Adjusting the front shock absorber assemblies ..........4-14 DESCRIPTION ..........3-1 Adjusting the rear shock absorber Left view ............
  • Page 9 OPERATION ..........6-1 PERIODIC MAINTENANCE AND MINOR Starting a cold engine ........ 6-1 REPAIR ............8-1 Starting a warm engine ......6-3 Owner’s manual and tool kit .......8-1 Operating the drive select lever and Periodic maintenance chart for the driving in reverse ........6-3 emission control system ......8-3 Engine break-in ..........
  • Page 10 Checking the front brake lever free SPECIFICATIONS ........10-1 play ............8-42 Adjusting the rear brake lever free play CONSUMER INFORMATION.......11-1 and checking the brake pedal position ... 8-42 Identification numbers .......11-1 Axle boots ..........8-44 Brake light switches ......... 8-45 Checking and lubricating the cables ..

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION EBU17534 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 hill. If you stall or roll backwards, follow the spe- Always be sure there are no obstacles or people cial procedure for braking described in this man- behind you when you operate in reverse. When ual. Dismount on the uphill side or to a side if it is safe to proceed in reverse, go slowly.
  • Page 14 When transporting the ATV in another vehi- EWB00070 WARNING cle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel Always operate your ATV in an area with ade- may leak out of the carburetor or fuel tank. quate ventilation.

  • 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.

  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly spring preload adjusting 1. Spark arrester ring 2. Tail/brake light 2. Fuel cock 3. Battery 3. Air filter case 4. Spark plug 4. Fuses 5. Rear brake fluid reservoir 5.

  • Page 19: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Left handlebar switches 3. Starter (choke) 4. Drive select lever 5. Main switch 6. Speedometer unit 7.

  • Page 20: Instrument And Control Functions

    EBU17732 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 21: Indicator Lights And Warning Light

    EBU17813 Indicator lights and warning light If the indicator light flashes under any other circum- stances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. EBU17860 Neutral indicator light “...

  • Page 22: Speedometer Unit

    Start the engine after making sure that the EBU26362 Speedometer unit warning light is out. Continuous use while the warning light is on may cause damage to the engine. EBU26591 On-Command four-wheel-drive indicator “ ” This indicator comes on when the On-Command four-wheel-drive switch is set to the “4WD”...

  • Page 23: Handlebar Switches

    Odometer and tripmeter modes EBU18061 Handlebar switches Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the trip- meter mode “TRIP” in the following order: ODO → TRIP → ODO To reset the tripmeter, select it by pushing the “SE- LECT”...
  • Page 24 EBU18100 EBU28221 Start switch “ ” On-Command four-wheel-drive switch Push this switch to crank the engine with the start- “2WD”/“4WD” This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice versa. ECB00050 NOTICE Select the appropriate drive according to the ter- See the starting instructions on page 6-1 prior rain and the conditions.

  • Page 25: Throttle Lever

    EBU18280 Throttle lever Once the engine is running, movement of the throt- tle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position. Because the throttle is spring- loaded, the ATV will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

  • Page 26: Speed Limiter

    This could cause an accident. Check the op- eration of the throttle lever before you start the engine. If the throttle does not work smoothly, check for the cause. Correct the problem be- fore riding the ATV or consult a Yamaha dealer. EBU18321 Speed limiter 1. Locknut 2.

  • Page 27: Front Brake Lever

    EBU18391 Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip. 1. Brake pedal 1. Front brake lever EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar.

  • Page 28: Drive Select Lever

    EBU18621 Drive select lever The drive select lever is used to shift your ATV into the forward, neutral, reverse and park positions. See the “Operating the drive select lever and driv- ing in reverse” section on page 6-3 for the drive se- lect lever operation.

  • Page 29: Fuel Cock

    ECB00070 NOTICE Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. EWB00310 WARNING Do not overfill the fuel tank. Fuel expands when it heats up.
  • Page 30 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 31: Starter (Choke)

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 32: Storage Compartment

    To install the seat Fit the slot in the seat onto the projection on the front cowling, insert the projections on the front of the seat into the seat holders, and then push on the seat at the rear. Make sure that the seat is securely fitted. 1.

  • Page 33: Adjusting The Front Shock Absorber Assemblies

    When storing any documents in the storage com- Do not exceed the maximum load of 100.0 kg partment, be sure to wrap them in a plastic bag so (220 lb) for the ATV. that they will not get wet. When washing the ATV, be careful not to let any water enter the storage Drain plugs are fitted at the bottom of the storage compartment.
  • Page 34 1. Special wrench Spring preload setting: Minimum (soft): 1. Spring preload adjusting ring Standard: 2. Position indicator Maximum (hard): A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-15...

  • Page 35: Adjusting The Rear Shock Absorber Assembly

    Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase A special wrench can be obtained at a Yamaha the spring preload and thereby harden the suspen- dealer to make this adjustment.
  • Page 36 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): 4-17...

  • Page 37: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 38 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, 8-39, 8-40, 8-42 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 39: 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 4-9.) specified level. Add oil as necessary. (See page EWB00520 8-25.) WARNING EBU19630 Do not overfill the fuel tank.

  • Page 40: Front And Rear Brakes

    Check that there is no free play in the front brake ly inward, there may be a leak in the brake system. lever. If there is free play, have a Yamaha dealer If there is any leakage, the brake system should be check the brake system.

  • Page 41: Throttle Lever

    Throttle lever Manufacturer/model: Check the operation of the throttle lever. It must MAXXIS/M938 open smoothly and spring back to the idle position Size: when released. Have a Yamaha dealer correct if AT23 x 10R12 necessary. Type: Tubeless EBU19812 The tires should be set to the recommended...

  • Page 42: Measuring The Tire Pressure

    • Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (2.5 kgf/cm², 36 psi) Rear: 250 kPa (2.5 kgf/cm², 36 psi) Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully.

  • Page 43: Tire Wear Limit

    EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly.

  • Page 44: Operation

    The corresponding indicator accident or injury. If there is a control or func- light should come on, if it does not come on, tion you do not understand, ask your Yamaha have a Yamaha dealer check the electrical cir- dealer.
  • Page 45 4. Use the starter (choke) in reference to the fig- 5. Apply the rear brake lever. ure: 6. Completely close the throttle lever and start Position (1): the engine by pushing the start switch. Cold engine start with ambient temperature below 5 °C (40 °F).

  • Page 46: Starting A Warm Engine

    The engine is warm when it responds normally to Make sure that the drive select lever is completely the throttle with the starter (choke) turned off. shifted into position. EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm.
  • Page 47 When in reverse, the reverse indicator light should come on. If the indicator light does not The drive select lever cannot be shifted into or from come on, have a Yamaha dealer check the elec- reverse or park without applying the brake pedal. trical circuit.

  • Page 48: Engine Break-In

    320 km (200 mi) or 20 engine break-in period, immediately have a hours of riding. For this reason, you should read Yamaha dealer check the ATV. the following material carefully. Since the engine is brand new, do not put an ex-...

  • Page 49: Accessories And Loading

    3. With the brake pedal applied, shift the drive may also be available on the market. However, select lever to the park position. it is not possible for Yamaha to test all non- Yamaha accessories, nor control over their qual- ity or suitability. Choose a genuine Yamaha ac- cessory, or one that is equivalent in design and quality.
  • Page 50 could make steering difficult, an accessory that If you are carrying cargo and towing a trailer, in- limits your ability to move around on the seat, or clude the tongue weight in the maximum ATV one that limits your view. load limit.
  • Page 51 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 52: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 53: Getting To Know Your Atv

    EBU26576 Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum performance until GETTING TO KNOW YOUR ATV you are totally familiar with the ATV’s handling and This ATV is intended for recreational use by expe- performance characteristics.
  • Page 54 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 55 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 56 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 57 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 58 Loading and accessories Always follow the instructions in your Own- As originally equipped, this ATV is not designed to er’s Manual for carrying cargo or pulling a carry cargo or tow a trailer. If you choose to add ac- trailer. cessories so that you can carry cargo or tow a trail- er, you must use common sense and good During operation...
  • Page 59 All parts and you or cause an accident. accessories added to this ATV should be gen- uine Yamaha or equivalent components de- Avoid wheelies and jumping. You may lose control signed for use on this ATV and should be of the ATV or overturn.

  • Page 60: Be Careful Where You Ride

    Do not park the ATV during or after operation EWB01510 WARNING in a place where others might be likely to touch it. Always avoid paved surfaces, including side- Do not operate, idle, or park the ATV in dry walks, driveways, parking lots and streets. grass, dry ground cover, or combustible ma- ATVs are designed for use on unpaved surfac- terials.
  • Page 61 While riding on unpaved public streets or roads Know the terrain where you ride. Ride cautiously in may be legal in your area, such operation can in- unfamiliar areas. Stay alert for holes, rocks, or crease the risk of collision with other vehicles. roots in the terrain, and other hidden hazards Watch carefully for other vehicles.
  • Page 62 EWB01540 When riding in an area where you might not easily WARNING be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket Do not operate on excessively rough, slippery as a trailer hitch. or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.

  • Page 63: Turning Your Atv

    With the engine idling, return the starter (choke) to the closed position, and shift the drive select lever into the forward position. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is ap- plied too abruptly, the front wheels may lift off the ground, resulting in a loss of directional control.
  • Page 64 EWB01570 WARNING Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions. As you approach a curve, slow down and begin to turn the handlebars in the desired direction.

  • Page 65: Climbing Uphill

    Improper riding procedures such as abrupt throttle EWB01580 WARNING changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the Never operate the ATV on hills too steep for the turn may cause the ATV to tip. If the ATV begins to ATV or for your abilities.
  • Page 66 Never go over the top of any hill at high EWB01600 WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never attempt to turn the ATV around on any of the hill. hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground.
  • Page 67 ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediately on the uphill side. EWB01811 WARNING Maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.

  • Page 68: Riding Downhill

    When this ATV is in 4WD, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the downhill side.

  • Page 69: Crossing A Slope

    Avoid going down a hill at an angle that to cross a sloping surface. Avoid slopes with slip- would cause the ATV to lean sharply to one pery surfaces or rough terrain that may upset your side. Go straight down the hill where possi- balance.

  • Page 70: Crossing Through Shallow Water

    Shift your weight to the uphill side of the EWB01640 WARNING ATV. Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
  • Page 71 Test your brakes after leaving the water. Do not plug to drain any water that may have accumu- continue to ride your ATV without verifying that you lated. Wash the ATV in fresh water if it has been have regained proper braking ability. operated in salt water or muddy conditions.
  • Page 72 1. V-belt cooling duct check hose (left front side of ATV) 1. Storage compartment drain plug 1. Drive select lever box check hose 1. V-belt case drain plug 7-21...

  • Page 73: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times.

  • Page 74: What To Do If

    On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control. WHAT TO DO IF... This section is designed to be a reference guide only.
  • Page 75 If your ATV can’t make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD –...

  • Page 76: Periodic Maintenance And Minor Repair

    EBU28782 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 77 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING...

  • Page 78: 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 79 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 80: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
  • Page 81 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours √ √ √ Swingarm • Check for excessive play, and correct if necessary. • Check for wear, cracks or other damage, and re- √...
  • Page 82 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Change. √ √ Final gear oil • Check ATV for oil leakage, and correct if neces- sary. •...
  • Page 83 Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.

  • Page 84: Removing And Installing Cowlings And Panels

    EBU26401 Removing and installing cowlings and panels The cowlings and panels shown need to be re- moved to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed.
  • Page 85 1. Speedometer unit coupler 1. Bolt (left side) 4. Remove cowling A by removing the bolts, nuts and washers. 1. Bolt (right side) 1. Bolt 8-10...
  • Page 86 To install the cowling 3. Pull off the handlebar cover. 1. Connect the speedometer unit couplers. ECB00740 NOTICE 2. Install cowling A by installing the bolts, nuts and washers. Do not disconnect the main switch coupler. 3. Install panel B. 4.
  • Page 87 5. Remove the cowling by removing the bolts. 1. Bolt (right side) 1. Bolt 6. Install the fuel tank cap by turning it clockwise. To install the cowling 1. Remove the fuel tank cap by turning it coun- terclockwise. 2. Install the cowling by installing the bolts. 3.
  • Page 88 EBU26412 Panel B To remove the panel Pull outward on the areas shown. Panel A To remove the panel Remove the bolt, and then take the panel off. 1. Panel B To install the panel Insert the projections on the panel into the slots in 1.
  • Page 89 1. Projection 1. Panel C 2. Slot 2. Bolt To install the panel Panel C Place the panel in the original position and install To remove the panel the bolts. Remove the bolts, and then take the panel off. Panel D To remove the panel Pull outward on the areas shown.

  • Page 90: Checking The Spark Plug

    EBU23211 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart.
  • Page 91 (the ideal color when the ATV is ridden normally). If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-16...

  • Page 92: Engine Oil And Oil Filter Cartridge

    If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4.
  • Page 93 4. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. 1. Dipstick 2. Maximum level mark 3. Minimum level mark 1. Engine oil filler cap 5. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to The engine oil should be between the minimum check the oil level.
  • Page 94 To change the engine oil (with or without oil fil- ter cartridge replacement) Skip steps 6–10 if the oil filter cartridge is not being 1. Place the ATV on a level surface. replaced. 2. Remove panel D. (See page 8-9.) 6.
  • Page 95 1. Oil filter wrench 1. O-ring An oil filter wrench is available at a nearby Yamaha Make sure that the O-ring is properly seated. dealer. 9. Install the new oil filter cartridge with an oil fil- 8. Apply a thin coat of engine oil to the O-ring of ter wrench, and then tighten it to the specified the new oil filter cartridge.
  • Page 96 12. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.43 US qt, 2.02 Imp.qt) With oil filter cartridge replacement: 2.40 L (2.54 US qt, 2.11 Imp.qt) 1.

  • Page 97: 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 in the periodic maintenance and lubrication chart.
  • Page 98 2. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil 2. Final gear oil filler bolt 3. Correct oil level 1. Final gear case guard 2. Bolt 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise 3.
  • Page 99 1. Final gear oil drain bolt 1. Final gear oil 2. Final gear oil filler bolt 5. Install the drain bolt, and then tighten it to the 3. Correct oil level specified torque. Recommended final gear oil: Tightening torque: See page 10-1. Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) ECB00420...

  • Page 100: Changing The Differential Gear Oil

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 101 The differential gear case capacity is greater than the recommended oil quantity, therefore the oil level cannot be accurately checked from the oil filler hole. Recommended differential gear oil: See page 10-1. Oil quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt) ECB00410 NOTICE 1.

  • Page 102: Coolant

    EBU23470 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. EBU27940 To check the coolant level 1. Place the ATV on a level surface. The coolant level must be checked on a cold en- 1.
  • Page 103 If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- erwise the effectiveness of the coolant will be reduced. The radiator fan is automatically switched on or off according to the coolant temperature in the radiator.
  • Page 104 3. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object as shown to prevent coolant from spilling on the footrest.) 1. Trough 4. Remove cowling A. (See page 8-9.) 5.
  • Page 105 6. Remove the coolant reservoir cap. 10. Connect the coolant reservoir hose. 7. Disconnect the hose on the coolant reservoir 11. Pour the recommended coolant into the reser- side, and then drain the coolant from the cool- voir to the maximum level mark, and then in- ant reservoir.

  • Page 106: Cleaning The Air Filter Element

    15. Start the engine, and then check for coolant leakage. If any leakage is found, have a Yamaha dealer check the cooling system. 16. Install the cowling. 17. Install the panels.
  • Page 107 2. Remove the seat. (See page 4-12.) 3. Remove the air filter case cover by unhooking the air filter case cover holders. 1. Air filter element 5. Pull off the air filter element lock plate, and then remove the sponge material from the air 1.
  • Page 108 ECB00440 NOTICE Do not twist the sponge material when squeez- ing it. 1. Air filter element frame 2. Sponge material 3. Air filter element lock plate 6. Wash the sponge material gently but thor- oughly in solvent. 8. Check the sponge material and replace it if EWB01940 damaged.

  • Page 109: Cleaning The Spark Arrester

    11. Insert the air filter element into the air filter will affect carburetor jetting with subsequent case, and then install the air filter case cover poor performance and possible engine over- by hooking the holders onto the air filter case. heating.

  • Page 110: V-Belt Cooling Duct Check Hose

    3. Tap the tailpipe lightly, and then use a wire EWB02340 WARNING brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside Do not start the engine when cleaning the of the tailpipe housing. spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire.

  • Page 111: V-Belt Case Drain Plug

    If water drains from the V-belt case after removing most carburetor adjustments should be left to a the plug, have a Yamaha dealer check the ATV as Yamaha dealer, who has the necessary profes- the water may affect other engine parts.
  • Page 112 Engine idling speed: tle stop screw in direction (a), and to decrease 1450–1550 r/min it, turn the screw in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 8-37...

  • Page 113: Adjusting The Throttle Cable Free Play

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

  • Page 114: Adjusting The Drive Select Lever Safety System Cable

    The drive select lever safety system cable stretch- es with use, which can result in improper function. Therefore, the safety system cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 115: Checking The Brake Fluid Level

    brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Front brake 1. Wear indicator groove The wheels need to be removed to check the brake pads.

  • Page 116: Changing The Brake Fluid

    To check the rear brake fluid level, remove cowling EBU24291 Changing the brake fluid B. (See page 8-9.) Have a Yamaha dealer change the brake fluid at Observe these precautions: the intervals specified in the TIP after the periodic When checking the fluid level, make sure that maintenance and lubrication chart.

  • Page 117: Checking The Front Brake Lever Free Play

    If there is free play, have a Replacement of brake components requires Yamaha dealer check the brake system. professional knowledge. These procedures should be performed by a Yamaha dealer. EBU26491 Adjusting the rear brake lever free play and checking the brake pedal position...
  • Page 118 3. Tighten the locknut. If the correct free play cannot be obtained, have a 1. Brake lever free play Yamaha dealer adjust it. 1. Loosen the locknut. 2. Turn the brake lever free play adjusting bolt in When adjusting the rear brake lever free play: direction (a) to increase the free play, and in Be sure not to step on the brake pedal.

  • Page 119: Axle Boots

    67.0–77.0 mm (2.64–3.03 in) above the top of the Replacement of brake components requires footboard bracket. If the brake pedal position is in- professional knowledge. These procedures correct, have a Yamaha dealer adjust it. should be performed by a Yamaha dealer. EBU24230 Axle boots...

  • Page 120: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. 1. Remove panel A. (See page 8-9.) 1. Brake light switch The brake light switch is properly adjusted when 2.

  • Page 121: Checking And Lubricating The Front And Rear Brake Levers

    EWB02130 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. EBU28711 Checking and lubricating the front and rear brake levers...

  • Page 122: Checking The Wheel Hub Bearings

    WARNING in a wheel hub or if a wheel does not turn smoothly, Battery electrolyte is poisonous and danger- have a Yamaha dealer check the wheel hub bear- ous, as it contains sulfuric acid, which can ings. cause severe burns. Avoid contact with skin, eyes or clothing.
  • Page 123 4. Pull the battery out of its compartment. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.
  • Page 124 To store the battery If the ATV will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary.

  • Page 125: Replacing A Fuse

    If you do not have access to a constant-voltage battery charger, have a Yamaha dealer charge your battery. EBU25324 Replacing a fuse 1. Headlight fuse 2. Ignition fuse 3. Auxiliary DC jack fuse (for optional auxiliary DC jack) 4.

  • Page 126: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical Specified fuses: circuits to check if the devices operate. Main fuse: 4. If the fuse immediately blows again, have a 30.0 A Yamaha dealer check the electrical system. Headlight fuse: EBU25541 15.0 A Replacing a headlight bulb Ignition fuse: If a headlight bulb burns out, replace it as follows.
  • Page 127 3. Remove the defective bulb from the headlight unit by pulling it out. EWB02220 WARNING A headlight bulb is hot when it is on and imme- diately after it is turned off. Wait for the bulb to cool before touching or removing it. You can be burned or a fire could start if the bulb touch- es something flammable.

  • Page 128: Adjusting A Headlight Beam

    ECB00690 5. Install the headlight bulb holder by aligning the NOTICE projections with the holes in the headlight unit, It is advisable to have a Yamaha dealer make pushing it inward, and turning it clockwise until this adjustment. it stops.

  • Page 129: Replacing The Tail/Brake Light Bulb

    1. Headlight beam adjusting bolt 1. Screw 2. Remove the defective bulb by pushing it in EBU25600 Replacing the tail/brake light bulb and turning it counterclockwise. If the tail/brake light bulb burns out, replace it as follows. 1. Remove the lens by removing the screws. 1.

  • Page 130: Removing A Wheel

    3. Insert a new bulb into the socket, push it in, 4. Remove the nuts from the wheel. and then turn it clockwise until it stops. 5. Remove the wheel. 4. Install the lens by installing the screws. EBU25701 ECB00700 Installing a wheel NOTICE 1.

  • Page 131: Troubleshooting

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

  • Page 132: 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 133 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 134: 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 135: 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 136 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-47.

  • Page 137: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Cylinder arrangement: Forward-inclined single cylinder Overall length: Displacement: 1978 mm (77.9 in) 421.0 cm³ Overall width: Bore × stroke: 1063 mm (41.9 in) 84.5 × 75.0 mm (3.33 × 2.95 in) Overall height: Compression ratio: 1095 mm (43.1 in) 10.00 :1 Seat height: Starting system:...
  • Page 138 Engine oil: Differential gear oil: Type: Type: SAE 5W-30 or SAE 10W-30 or SAE 10W-40 or SAE SAE 80 API GL-4 Hypoid gear oil 15W-40 or SAE 20W-40 or SAE 20W-50 Quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt) Cooling system: 50 ˚C Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt, 0.22 Imp.qt)
  • Page 139 Clutch: Manufacturer/model: MAXXIS/M937 Clutch type: Rear tire: Wet, centrifugal automatic Transmission: Type: Tubeless Primary reduction system: Size: V-belt AT23 x 10R12 Secondary reduction system: Manufacturer/model: Shaft drive MAXXIS/M938 Secondary reduction ratio: 39/24 × 24/18 × 33/9 (7.944) Loading: Transmission type: Maximum loading limit: V-belt automatic 100.0 kg (220 lb)
  • Page 140 Rear wheel: Wheel travel: 180 mm (7.1 in) Wheel type: Electrical system: Panel wheel Rim size: Ignition system: 12 x 7.5AT DC. CDI Front brake: Charging system: AC magneto Type: Battery: Dual disc brake Operation: Model: Right hand operation YTX20L-BS Recommended fluid: Voltage, capacity: DOT 4...
  • Page 141 Fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Ignition fuse: 10.0 A Auxiliary DC jack fuse: 10.0 A Backup fuse: 10.0 A Four-wheel-drive motor fuse: 3.0 A 10-5...

  • 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 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 144 1. Model label 11-3...
  • Page 145 INDEX Differential gear oil, changing ........8-25 Drive select lever ............4-9 Accessories and loading ..........6-6 Drive select lever and driving in reverse ......6-3 Air filter element, cleaning ..........8-31 Drive select lever safety system cable, adjusting ..8-39 Axle boots ..............
  • Page 146 Specifications ............... 10-1 Speed limiter ..............4-7 Key identification number ..........11-1 Speedometer unit ............4-3 Starter (choke) ............. 4-12 Label locations ............... 2-1 Start switch ..............4-5 Light switch ..............4-5 Steering shaft, lubricating ..........8-47 Storage ................9-2 Main switch ..............
  • Page 148 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2008.05-0.3×1 CR...

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