Yamaha YFZ450RSSE Owner's Manual
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Yamaha YFZ450RSSE 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
YFZ450RSSE
1TD-F8199-6A

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Summary of Contents for Yamaha YFZ450RSSE

  • 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 YFZ450RSSE 1TD-F8199-6A...
  • Page 2 Original instructions Notice originale Manual original PRINTED IN USA 2014.01-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFZ450RSSE WARNING This ATV should not be ridden by anyone under 16 years of age. 1TD-F8199-6A-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFZ450R (YFZ450RSS) (JY4AJ74W0D0500101–)
  • 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 EBU17331 IMPORTANT MANUAL INFORMATION EBU17343 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 Please check your local riding laws and regulations before operating this ATV. EBU17411 YFZ450RSSE OWNER’S MANUAL ©2013 by Yamaha Motor Co., Ltd. 1st edition, December 2013 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 8: Table Of Contents

    EBU17421 TABLE OF CONTENTS LOCATION OF THE WARNING AND Seat ............4-10 SPECIFICATION LABELS ......1-1 Adjusting the front shock absorber assemblies..........4-11 SAFETY INFORMATION ........2-1 Adjusting the rear shock absorber assembly ..........4-16 DESCRIPTION..........3-1 Handlebar position ........4-24 Left view............3-1 Right view............3-1 PRE-OPERATION CHECKS ......
  • Page 9 Accessories and loading......6-6 Checking the spark plug......8-13 Engine oil and oil filter element....8-14 RIDING YOUR ATV ........7-1 Coolant ............. 8-20 GETTING TO KNOW YOUR ATV ....7-2 Cleaning the air filter element ....8-21 RIDE WITH CARE AND GOOD Cleaning the spark arrester ......
  • Page 10 Lubricating the upper and lower arm pivots ............8-41 Lubricating the steering shaft ....8-42 Battery............8-42 Replacing the fuse ........8-45 Replacing a headlight bulb .......8-45 Adjusting a headlight beam ......8-48 Tail/brake light...........8-48 Removing a wheel........8-48 Installing a wheel........8-49 Troubleshooting ........8-49 Troubleshooting charts ......8-51 CLEANING AND STORAGE ......9-1 Cleaning ............9-1 Storage............9-2...

  • Page 11: Location Of The Warning And Specification Labels

    Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a re- placement label from your Yamaha dealer. For Europe...
  • Page 12 YAMAHA 1HP-F811R-00 YAMAHA 1P0-F816R-00...
  • Page 13 35.0 kPa 0.35 kgf/cm² 0.35 kgf/cm² 5.0 psi 5.0 psi YAMAHA 3C2-F816P-00 1TD-F816M-M0 Use PREMIUM unleaded gasoline with min. 97 octane (RON). Nur Super Bleifrei mit Mindestoktanzahl 97 (ROZ) tanken. Utilice gasolina sin plomo que tenga como mínimo 97 octanos(RON).
  • Page 14 YFZ450R 2014 30.0 kW YAMAHA MOTOR CO., LTD. 184 kg 2500 SHINGAI, IWATA, JAPAN 1TD-F155A-10 1HP-F2259-21...
  • Page 15 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
  • Page 16 This unit contains high-pressure nitrogen Turning 4WD-LOCK gas. (“DIFF.LOCK”) takes more effort. Operate at a slow speed and allow extra Mishandling can cause an explosion. Do not incinerate, puncture or open. time and distance for maneuvers to avoid loss of control. This pictogram shows the loading limits and/or maximum load capacity for this ATV.
  • Page 17 Year of construction Model Name ****** **** *** kW YAMAHA MOTOR CO., LTD. Max. Power *** kg 2500 SHINGAI, IWATA, JAPAN Mass In Running Order...
  • Page 18 For Oceania...
  • Page 19 YAMAHA 1P0-F816L-00 YAMAHA 4XE-F1568-10...
  • Page 20 • Maximum weight capacity : 100 kg (220 lbs.) Includes weight of operator, cargo and accessories. 1TD-F816M-00 1HP-F2259-21 WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. YAMAHA 3C2-F151H-00 1-10...

  • Page 21: Safety Information

    EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Never allow a child under age 16 to operate an EBU29374 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 22  Never operate at speeds too fast for your skills  Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 23  Never operate an ATV in fast flowing water or in technique described in this manual on level ground. Avoid crossing the side of a steep hill if water deeper than that recommended in this possible. manual. Remember that wet brakes may have ...
  • Page 24 In the event of an accident tention. If necessary, contact your riding party 1. If serious injuries are incurred, you may be or local authorities to let them know where safer staying next to your vehicle; it may you are and what has happened. shield you from oncoming riders.
  • Page 25 This im- While you may find aftermarket products similar in proper position limits the freedom of movement design and quality to genuine Yamaha accesso- of the operator and may limit control ability, ries, recognize that some aftermarket accessories...
  • Page 26  Do not run engine outdoors where engine EWB00073 WARNING exhaust can be drawn into a building through openings such as windows and doors. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nau- sea, confusion, and eventually death.

  • Page 27: Description

    EBU17681 DESCRIPTION EBU17691 EBU17701 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 28: Controls And Instruments

    EBU17713 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 29: Instrument And Control Functions

    EBU17735 INSTRUMENT AND CONTROL FUNCTIONS EBU29912 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 switch is on, and the engine can be started. The key cannot be removed.

  • Page 30: 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 electrical circuit. 1. Fuel level warning light “ ”...

  • Page 31: Handlebar Switches

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

  • Page 32: Throttle Lever

    switch to stop the engine in an emergency situa- EBU18283 Throttle lever tion. The engine will not start or run when this Once the engine is running, pushing the throttle le- switch is set to “ ”. ver will increase the engine speed. EBU18102 Regulate the speed of the ATV by varying the Start switch “...

  • Page 33: Speed Limiter

    EBU18324 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 available and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 34: Brake Lever

    1. Brake lever 1. Clutch lever 2. Locknut 3. Brake lever position adjusting bolt EBU18424 Brake lever 4. Distance between brake lever and handlebar grip The brake lever is located on the right handlebar. EBU18433 To apply the front brake, pull the brake lever to- Brake pedal ward the handlebar grip.

  • Page 35: Parking Brake Lever

    1. Brake pedal 1. Parking brake lever (locked position) EBU18521 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 36: Shift Pedal

    EWB00221 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 37: Fuel

    of sparks, open flames, or other sources of ignition such as the pilot lights of water heat- ers 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 38: Seat

    3.4 L (0.90 US gal, 0.75 Imp.gal) rings, as well as to the exhaust system. 3. Wipe up any spilled fuel immediately. Your Yamaha engine has been designed to use NOTICE: Immediately wipe off spilled fuel premium unleaded gasoline with a research oc- with a clean, dry, soft cloth, since fuel may tane number of 97 or higher.

  • Page 39: Adjusting The Front Shock Absorber Assemblies

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat EBU30051 Insert the projections on the front of the seat into Adjusting the front shock absorber as- the seat holders and push down on the seat at the semblies rear.
  • Page 40 would be advisable to check the number of clicks EWB02492 WARNING or turns of each damping force adjusting mecha-  Suspension components become hot during nism and to modify the specifications as neces- 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 41  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 42 Rebound damping force Rebound damping setting: Turn the rebound damping force adjusting screw Minimum (soft): in direction (a) to increase the rebound damping 30 click(s) in direction (b)* force and thereby harden the damping, and in di- Standard: rection (b) to decrease the rebound damping force 16 click(s) in direction (b)* and thereby soften the damping.
  • Page 43 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 direction (a). To decrease the compression damping force and thereby soften the compres- sion damping, turn the adjusting screw in direction (b).

  • Page 44: 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. 20 click(s) in direction (b)*...
  • Page 45 ECB00091 NOTICE Never turn an adjusting mechanism beyond the minimum and maximum settings. Although the total number of clicks or turns of a damping force adjusting mechanism may not ex- actly match the following specifications due to small differences in production, the actual number of clicks or turns always represents the entire ad- 1.
  • Page 46 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 in- take duct.
  • Page 47 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 48 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 49 15. Install the air filter case holding plate by in- Tightening torque: stalling the bolts and collars, and then tighten Locknut: the 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 50 Compression damping force Remove the seat to make this adjustment. (See page 4-10.) If the adjustment is difficult, it may be necessary to remove panels A and C. (See page 8-10.) Compression damping force (for fast compres- sion damping) To increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting bolt in direction (a).
  • Page 51 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 52: Handlebar Position

    Yamaha deal- er for any service. EBU29403 Handlebar position The handlebar can be adjusted to one of two po- sitions to suit the rider’s preference. Have a Yamaha dealer adjust the position of the handle- bar. 4-24...

  • Page 53: 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 54 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, 8-28, 8-29, 8-31 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.
  • Page 55 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate lever pivoting points Brake and clutch levers 8-39 if 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 56: Fuel

    Yamaha dealer check the brake sys- tem. Brake lever and brake pedal  Check that there is no free play in the brake le- ver. If there is free play, have a Yamaha dealer check the brake system.

  • Page 57: Throttle Lever

    Set tire [EWB02542] when released. Have a Yamaha dealer correct if pressures to the following specifications: necessary. EBU19771 Drive chain Check the condition of the drive chain and check the drive chain slack.
  • Page 58 Recommended tire pressure: Front 35.0 kPa (0.350 kgf/cm², 5.0 psi) Rear 35.0 kPa (0.350 kgf/cm², 5.0 psi) Minimum tire pressure: Front 32.0 kPa (0.320 kgf/cm², 4.6 psi) Rear 32.0 kPa (0.320 kgf/cm², 4.6 psi) Maximum tire seating pressure: 1. Low-pressure tire gauge Front 250 kPa (2.5 kgf/cm², 36 psi) Tire wear limit...

  • Page 59: Chassis Fasteners

    After extensive tests, only the tires listed below EBU19841 have been approved for this model by Yamaha Chassis fasteners Motor Manufacturing Corporation of America. Make sure that all nuts, bolts and screws are properly tightened.

  • Page 60: Instruments, Lights And Switches

    EBU19851 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.

  • Page 61: Operation

    3. Shift the transmission into neutral. The neutral accident or injury. indicator light should come on, if it does not come on, have a Yamaha dealer check the EBU29953 Starting the engine electrical circuit.

  • Page 62: Shifting

    4. Completely close the throttle lever and start When it stops, it will be in first gear. Raise the ped- the engine by pushing the start switch. al slightly to reach the neutral position, and then release the clutch. If the engine fails to start, release the start switch, then push it again.
  • Page 63 3. Shift into first gear, and then release the EBU20652 To decelerate brake. NOTICE: Always close the throttle When slowing down or stopping, release the before shifting gears, otherwise damage throttle and apply the brakes smoothly and evenly. to the engine and drive train may result. As you slow down, shift to a lower gear.

  • Page 64: Engine Break-In

    There is never a more important period in the life engine break-in period, immediately have a of 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 65: 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 66: Accessories And Loading

    An accessory which can shift position and accessories or offer other modifications for or come off while you are riding could affect Yamaha vehicles. Yamaha is not in a position to your ability to control the ATV. test the products that these aftermarket compa- ...
  • Page 67  If you are carrying cargo and towing a trailer, in- EBU20942 Loading clude the tongue weight in the maximum ATV EWB00821 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 68: Riding Your Atv

    EBU21142 RIDING YOUR ATV...

  • Page 69: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EBU21618 Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01382 This ATV is intended for recreational use by expe- WARNING rienced operators only. This section, Riding your  Do not operate this ATV or allow anyone else ATV, provides general ATV riding instructions for to operate it without proper instruction.
  • Page 70 the time to learn the basic techniques well before This ATV is designed to carry the operator only attempting more difficult maneuvers. Become fa- – passengers prohibited. miliar with this ATV at slow speeds first, even if you The long seat is to allow the operator to shift posi- are an experienced operator.
  • Page 71 Apparel Always wear the following to reduce risk of injury in an accident:  Approved motorcycle helmet that fits properly  Eye protection (goggles, helmet face shield, or protective eyewear)  Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 72 fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-5.) Pre-operation checks Always inspect your ATV each time you use it to...
  • Page 73  Do not exceed the maximum loading limits During operation for the vehicle (see “MAXIMUM LOADING Always keep your feet on the footrests during op- LIMIT” below or vehicle labeling). eration; otherwise, they may contact the rear  Make sure the load does not interfere with wheels.
  • Page 74 ATV should the engine has stopped. To reduce the risk of fire be genuine Yamaha or equivalent components during operation or after leaving the ATV, do not designed for use on this ATV and should be in- let brush, grass and other materials collect under stalled and used according to instructions.

  • Page 75: Be Careful Where You Ride

    next to other hot parts. Check under the vehicle BE CAREFUL WHERE YOU RIDE after operating in areas where combustible mate- This ATV is designed for use on unpaved surfaces rials may have collected. Do not idle or park the only.
  • Page 76 Watch carefully for other vehicles. Make sure you have enough time to react to hidden rocks, know your country’s laws and regulations before bumps, or holes. Go slowly and be extra care- you ride on unpaved public streets or roads. Do ful when operating on unfamiliar terrain.
  • Page 77 terrain could cause loss of traction or ATV con- trol, which could result in an accident, includ- ing an overturn. [EWB01542] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 78: Turning Your Atv

    NOTICE: Do not shift gears without Select a large, flat, unpaved area to become famil- trol. [EWB02632] iar with your ATV. Make sure that this area is free releasing the throttle. Damage to the engine or of obstacles and other riders. You should practice drive train may occur.
  • Page 79 To achieve maximum traction on unpaved surfac- es, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning tech- nique must be used to allow the ATV to make turns quickly and easily.

  • Page 80: Climbing Uphill

     Shift your weight forward. Once you have learned this technique, you should  Never open the throttle suddenly or make be able to perform it at higher speeds or in tighter curves. sudden gear changes. The ATV could flip Improper riding procedures such as abrupt throt- over backwards.
  • Page 81 Do not attempt to climb hills until you have mas- tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
  • Page 82 It is important when climbing a hill to make sure If you start to roll backwards, DO NOT apply the that your weight is transferred forward on the ATV. rear brake, and apply the front brake gradually. This can be accomplished by leaning forward and, The ATV could easily tip over backwards.

  • Page 83: Riding Downhill

     Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills.  Shift your weight backward and to the up side of the hill.

  • Page 84: Crossing A Slope

    Whenever possible, ride your ATV straight down- CROSSING A SLOPE hill. Avoid sharp angles which could allow the ATV EWB01633 WARNING to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- Improperly crossing hills or turning on hills stacles which may appear.

  • Page 85: Crossing Through Shallow Water

    As you travel across a slope, lean your body in the CROSSING THROUGH SHALLOW WATER uphill direction. It may be necessary to correct the EWB01642 WARNING steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on Operating this vehicle through deep or fast- slopes, be sure not to make sharp turns either up flowing water can lead to loss of control or an...
  • Page 86 After riding your ATV in water, be sure to drain the Test your brakes after leaving the water. If neces- trapped water by removing the check hose at the sary, apply them several times to let friction dry bottom of the air filter case. NOTICE: Undrained out the linings.

  • Page 87: Riding Over Rough Terrain

    accident. Be sure to keep your feet firmly mounted on the footrests at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01663 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 88: What To Do If

    To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain If the rear wheels of your ATV start to slide side- should be chosen carefully before attempting ways, control can usually be regained (if there is...

  • Page 89: What To Do

     If your ATV is traversing a sloping surface: WHAT TO DO...  If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.

  • Page 90: 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 91: Owner's Manual And Tool Kit

    Make sure to protect the owner’s If you do not have the tools or experience required manual by putting it in the plastic bag, then by for a particular job, have a Yamaha dealer perform placing the bag in the document pouch. it for you.

  • Page 92: 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 93 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (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 94: 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 95 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses •...
  • Page 96 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours √ √ √ Drive chain roller • Check for wear and replace if necessary. • Make sure that all nuts, bolts, and screws are √...
  • Page 97 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours Moving parts and √ √ √ √ • Lubricate. cables • Check operation. • Check throttle lever free play, and adjust if neces- √...
  • Page 98 • Replace the brake hoses every four years and if cracked or damaged.

  • Page 99: Removing And Installing The Cowling And Panels

    EBU30131 Removing and installing the cowling and panels The cowling 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 100 5. Install the fuel tank cap by turning it clock- wise. 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 101 Panels B and C To remove a panel 1. Remove panel A. 2. Pull the panel off. 2. Install panel A. Cowling 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 102: 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 103: 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 104 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 temperature. 3. Remove the engine oil tank filler cap, and wipe the engine oil dipstick off with a clean rag.
  • Page 105 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 106 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 107 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 108 11. Install the crankcase engine oil drain bolt, the engine oil tank drain bolt and their new gas- Be sure to wipe off spilled oil on any parts after the ket, and then tighten the bolts to their speci- engine and exhaust system have cooled down. fied torques.

  • Page 109: 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 110: 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 111 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 4-10.) 5. Remove the air filter element together with 3.
  • Page 112 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 113 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 hole in the air filter element frame. NOTICE: ity foam air filter oil to the sponge material.

  • Page 114: Cleaning The Spark Arrester

    16. Install the air filter case cover by hooking the holders onto the air filter case. 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 areas.
  • Page 115 1. Tailpipe cover 1. Bolt 2. Bolt 2. Retainer 3. Tailpipe 2. Remove the retainer by removing the bolts, 4. Gasket and then remove the tailpipe and gasket from 3. Tap the tailpipe lightly, and then use a wire the muffler. brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing.

  • Page 116: Adjusting The Throttle Lever Free Play

    Tightening torque: Tailpipe cover bolt: 8 Nm (0.8 m·kgf, 5.8 ft·lbf) EWB02341 WARNING Do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire. Always let the exhaust system cool prior to 1.

  • Page 117: 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). To decrease the throttle lever free brication chart.

  • Page 118: Checking The Brake Fluid Level

    If a brake pad has worn to the point that the wear indicator grooves have almost dis- that the wear indicator grooves have almost dis- appeared, have a Yamaha dealer replace the appeared, have a Yamaha dealer replace the brake pads as a set.
  • Page 119 Front brake To check the rear brake fluid level, remove the seat. (See page 4-10.) Specified brake fluid: DOT 4 EWB02721 WARNING Improper maintenance can result in loss of braking ability. Observe these precautions:  Insufficient brake fluid may allow air to enter 1.

  • Page 120: Changing The Brake Fluid

    If the brake fluid level goes down sud- denly, have a Yamaha dealer check the cause be- fore further riding. EBU24293 Changing the brake fluid...

  • Page 121: Checking The Brake Pedal Height

    The top of the brake pedal should be positioned 11.7 mm (0.46 in) below the top of the footrest as shown. If the brake pedal is not positioned as specified, have a Yamaha dealer adjust it. 1. Adjusting bolt 2. Cable length “A”...

  • Page 122: Brake Light Switches

    If the cable length cannot be adjusted to specifi- again. cation, consult a Yamaha dealer. 6. Tighten the locknut on the brake cable. EBU24744 7. Slide the rubber cover to its original position.

  • Page 123: Adjusting The Clutch Lever Free Play

    13.0 mm (0.31–0.51 in) as shown. If the free play is switch should be adjusted by a Yamaha dealer. incorrect, adjust it as follows. Turn the rear brake light switch adjusting nut while holding the brake light switch in place.

  • Page 124: Drive Chain Slack

    6. Tighten the locknut. 7. Slide the rubber cover to its original position. If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism. 8-35...
  • Page 125 4. Hole To adjust the drive chain slack 1. Place the ATV on a level surface. A rod can be obtained at a Yamaha dealer to make 2. Loosen the rear wheel axle pinch bolts. this adjustment. 3. Insert a rod of a diameter of 8 mm (0.3 in) and a length of 10 cm (4 in) into one of the holes in 4.

  • Page 126: Lubricating The Drive Chain

    prevent this from occurring, keep the drive EBU24883 Lubricating the drive chain chain slack within the specified limits. The drive chain must be cleaned and lubricated at [ECB00543] the intervals specified in the periodic maintenance 6. Pull the rod out, and then tighten the rear axle and lubrication chart, otherwise it will quickly wear pinch bolts to the specified torque in the or- out, especially when riding in dusty or wet areas.

  • Page 127: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Yamaha cable lubricant or other suitable cable lubricant EWB02582 WARNING  Inspect cables frequently and replace if damaged. Corrosion can result when the ca- 1.

  • Page 128: Checking And Lubricating The Brake And Clutch Levers

    Brake lever Checking the shift pedal The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle. EBU28872 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.

  • Page 129: Checking The Wheel Hub Bearings

    Lithium-soap-based grease EBU24996 Lubricating the swingarm pivots The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the pe- EBU24964 riodic maintenance and lubrication chart. Checking the wheel hub bearings The front and rear wheel hub bearings must be...

  • Page 130: Lubricating The Upper And Lower Arm Pivots

    Left side EBU25034 1. Upper grease nipple Lubricating the upper and lower arm 2. Lower grease nipple pivots The upper and lower arm pivots must be lubricat- ed at the intervals specified in the periodic main- tenance and lubrication chart. For parts equipped with a grease nipple, use a grease gun.

  • Page 131: Lubricating The Steering Shaft

    Antidote: The steering shaft must be lubricated by a EXTERNAL: Flush with water. Yamaha dealer at the intervals specified in the pe- INTERNAL: Drink large quantities of water or riodic maintenance and lubrication chart. milk. Follow with milk of magnesia, beaten egg or vegetable oil.
  • Page 132 [ECB01002] 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 elec- trical accessories.
  • Page 133 2. Connect the positive battery lead first, then ECB00932 NOTICE connect the negative battery lead by installing their bolt. NOTICE: When installing the bat- To charge a VRLA (Valve Regulated Lead Acid) tery, the main switch must be off, and the battery, a special (constant-voltage) battery charger is required.

  • Page 134: Replacing The Fuse

    1. Fuse 4. If the fuse immediately blows again, have a 2. Spare fuse Yamaha dealer check the electrical system. The fuse holder is located under the seat. (See page 4-10.) EBU30871 If the fuse is blown, replace it as follows.
  • Page 135 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the burnt-out bulb. 1. Headlight unit 2. Bolt 2. Remove the headlight bulb holder cover. 1. Headlight bulb holder 4. Place a new headlight bulb into position. NOTICE: Do not touch the glass part of the headlight bulb to keep it free from oil, oth- erwise the transparency of the glass, the...
  • Page 136 1. Do not touch the glass part of the bulb. 1. Headlight bulb holder cover 2. “TOP” mark 5. Install the headlight bulb holder by pushing it 7. Place the headlight unit in the original posi- in and turning it clockwise. tion, and then install the bolt.

  • Page 137: Adjusting A Headlight Beam

    ECB00691 If the tail/brake light does not come on, have a NOTICE Yamaha dealer check it. It is advisable to have a Yamaha dealer make this adjustment. EBU25652 Removing a wheel To raise a headlight beam, turn the headlight 1.

  • Page 138: Installing A Wheel

    The following troubleshooting charts represent quick and easy procedures for checking these vi- tal systems yourself. However, should your ATV require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the ATV properly.
  • Page 139 EWB02281 WARNING Do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. 8-50...

  • Page 140: Troubleshooting Charts

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the compression. 4. Compression The engine does not start. There is compression.
  • Page 141 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 recommended coolant as soon as possible.

  • Page 142: Cleaning And Storage

    EBU25861 CLEANING AND STORAGE ter pressure may cause water seepage EBU25903 Cleaning and deterioration of wheel bearings, Frequent, thorough cleaning of your ATV will not brakes, transmission seals and electrical only enhance its appearance but will improve its devices. Many expensive repair bills have general performance and extend the useful life of resulted from improper high-pressure de- many components.

  • Page 143: Storage

    abrasives which may mar the paint or protec- Specified amount: tive finish. When finished cleaning, start the 7.5 ml of stabilizer to each liter of fuel (or 1 engine and let it idle for several minutes. oz of stabilizer to each gallon of fuel) EBU27262 3.
  • Page 144 tively, turn the wheels a little every month in order to prevent the tires from becoming de- graded in one spot. 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.

  • Page 145: Specifications

    EBU25962 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 1795 mm (70.7 in) Liquid cooled 4-stroke, DOHC Overall width: Cylinder arrangement: 1240 mm (48.8 in) Single cylinder Overall height: Displacement: 1065 mm (41.9 in) 449 cm³ Bore × stroke: Seat height: 95.0 ×...
  • Page 146 Type: Fuel: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- Recommended fuel: Premium unleaded gasoline only Fuel tank capacity: 130 ˚F 10.0 L (2.64 US gal, 2.20 Imp.gal) Fuel reserve amount: SAE 5W-30 3.4 L (0.90 US gal, 0.75 Imp.gal) Fuel injection: SAE 10W-30 Throttle body:...
  • Page 147 Operation: Manufacturer/model: Left foot operation MAXXIS/MS22 Gear ratio: Loading: 1st: Maximum loading limit: 35/14 (2.500) 100.0 kg (220 lb) 2nd: (Total weight of rider, cargo, accessories, and tongue) 30/15 (2.000) Tire air pressure (measured on cold tires): 3rd: Recommended: 31/19 (1.632) Front: 4th: 35.0 kPa (0.350 kgf/cm², 5.0 psi)
  • Page 148 Operation: Battery: Right hand operation Model: Specified brake fluid: YTZ7S DOT 4 Voltage, capacity: Rear brake: 12 V, 6.0 Ah Type: Headlight: Disc brake Bulb type: Operation: Krypton bulb Bulb voltage, wattage × quantity: Right foot operation Specified brake fluid: Headlight: DOT 4 12 V, 30.0/30.0 W ×...
  • Page 149 EBU30402 For Europe only The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of work-force include the characteristics of the work room, the other sources of noise, etc.

  • Page 150: Consumer Information

    Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 151 1. Model label 11-2...

  • Page 152: Index

    INDEX Drive chain slack ............8-35 Accessories and loading ..........6-6 Air filter element, cleaning ..........8-21 Engine break-in .............. 6-4 Engine oil ............... 5-4 Engine oil and oil filter element ........8-14 Battery ................8-42 Engine, start ..............6-1 Brake and clutch levers, checking and lubricating ..8-39 Engine stop switch ............
  • Page 153 Model label ..............11-1 Tail/brake light ............. 8-48 Neutral indicator light ............. 4-2 Throttle lever ............4-4, 5-5 Throttle lever free play, adjusting ........ 8-27 Tires ................5-5 Owner’s manual and tool kit .......... 8-2 Troubleshooting ............8-49 Troubleshooting charts ..........8-51 Parking ................
  • Page 154 EBU26173 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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