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Yamaha YFM45FGX Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM45FGX
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-21-46
17S-F8199-10

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Summary of Contents for Yamaha YFM45FGX

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45FGX WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-21-46 17S-F8199-10...
  • Page 2 EBU17091...
  • Page 3 Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

  • Page 4: Important Manual Information

    EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or...

  • Page 5: Important Notice

    EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 6: Table Of Contents

    Throttle lever ..........4-11 EWB00010 WARNING Speed limiter ..........4-12 Front brake lever ........4-13 Indicates a potential hazard that could result in serious injury or death. Brake pedal and rear brake lever .....4-14 Drive select lever ........4-14 Recoil starter ..........4-15 Fuel tank cap ..........4-16 EBU17420 Fuel ............4-16 TABLE OF CONTENTS...
  • Page 7 Throttle lever ..........5-6 CROSSING THROUGH SHALLOW Tires ............5-6 WATER............7-28 Measuring the tire pressure ....... 5-7 RIDING OVER ROUGH TERRAIN....7-30 Tire wear limit ..........5-8 SLIDING AND SKIDDING ......7-31 Chassis fasteners ........5-9 WHAT TO DO IF........7-32 Instruments, lights and switches ....5-9 WHAT TO DO..........7-33 OPERATION ..........
  • Page 8 ........8-47 Noise regulation ........11-3 Checking and lubricating the brake Maintenance record ........11-4 pedal ............8-48 YAMAHA MOTOR CORPORATION, Checking the wheel hub bearings .... 8-48 U.S.A. ATV LIMITED WARRANTY ..11-5 Lubricating the drive shaft universal YAMAHA EXTENDED SERVICE joint ............

  • Page 9: Safety Information

    EBU17430 SAFETY INFORMATION EBU17482 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 10 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 11 steady speed when climbing a hill. If you stall or Always be sure there are no obstacles or people roll backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 12 EWB00021 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- POTENTIAL HAZARD oline in your eyes, seek medical help Improper handling of gasoline. immediately. If gasoline spills on your skin, WHAT CAN HAPPEN wash with soap and water.
  • Page 13 WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad- equate ventilation.

  • Page 14: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 15 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.

  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 1. Trailer hitch receiver 2. Fuel cock 2. Rear shock absorber assembly spring preload adjusting ring 3. Recoil starter 3. Spark arrester 4. Throttle stop screw 4. Storage compartment and tool kit 5.

  • Page 19: Controls And Instruments

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

  • Page 20: Instrument And Control Functions

    EBU17722 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light 1.

  • Page 21: Indicator Lights And Warning Light

    10 seconds or more. NOTE: 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 Start the engine after making sure that the EBU17970 Park indicator light “ ” warning light is out. Continuous use while This indicator light comes on when the transmis- the warning light is on may cause damage to sion is in the park position. the engine.

  • Page 23: Multifunction Display

    EBU18031 a clock Multifunction display an hour meter (which shows the total time the key has been turned to “ON”) Odometer and tripmeter modes Pushing the “TRIP/ODO” button switches the dis- play between the odometer mode “ODO” and the tripmeter modes “A” and “B” in the following order: ODO →...

  • Page 24: Fuel Gauge

    To set the clock NOTE: 1. Set the display to the clock mode. If the ATV runs out of fuel, move the fuel cock lever 2. Push the “ ”/“ ” button until the clock starts to the “RES” position. Approximately 4.5 L (1.19 flashing.
  • Page 25 EBU18080 ECB00040 Engine stop switch “ ” CAUTION: Set this switch to “ ” before starting the engine. Do not use the headlights with the engine The engine stop switch controls the ignition and turned off for an extended period of time, oth- stops the engine when it is running.
  • Page 26 This ATV is equipped with a switch to change from indicate a malfunction in the electrical system. In two-wheel drive to four-wheel drive and vice-versa. this case, take the ATV to a Yamaha dealer at the Select the appropriate drive according to the ter- first opportunity.
  • Page 27 “4WD” (four-wheel drive): Power is supplied to EWB00120 WARNING the rear and front wheels. To change from two-wheel drive to four-wheel POTENTIAL HAZARD drive, stop the ATV and push the switch in to the Changing from two-wheel drive to four- “4WD”...
  • Page 28 EBU18243 To lock the differential gear in four-wheel drive, On-Command differential gear lock switch make sure the On-Command four-wheel-drive “4WD”/“LOCK” switch is pushed in to the “4WD” position. This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive. Select the appropriate switch position according to the terrain and the conditions.
  • Page 29 WHAT CAN HAPPEN The ATV handles differently in four-wheel drive than in differential gear lock in some circumstances. Changing from four-wheel drive to differential gear lock or vice-versa while moving may cause the ATV to handle differently unexpectedly. This could distract the operator and increase the risk of losing control and causing an accident.

  • Page 30: Throttle Lever

    EWB00101 Riding before the differential gear lock is proper- WARNING ly engaged (e.g., when the indicator and indica- tor light are flashing) will cause the engine speed POTENTIAL HAZARD to be limited until engagement is complete. Riding too fast while the ATV is in four- When the ATV is in four-wheel-drive differential wheel-drive differential gear lock.

  • Page 31: Speed Limiter

    Check the operation of the throttle lever be- fore you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. EBU18311 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 32: Front Brake Lever

    HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). (See page 8-37.) EBU18391 Front brake lever The front brake lever is located on the right handle- bar.

  • Page 33: Brake Pedal And Rear Brake Lever

    EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.

  • Page 34: Recoil Starter

    1. Drive select lever 1. Recoil starter EWB00290 EBU18680 WARNING Recoil starter Firmly grasp the handle and pull slightly until en- POTENTIAL HAZARD gagement can be felt. Then pull forcefully, being Starting the engine without setting the drive careful not to pull the rope all the way out. select lever to the park position.

  • Page 35: Fuel Tank Cap

    EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Fuel level 2. Fuel tank filler tube Recommended fuel: UNLEADED GASOLINE ONLY 1. Fuel tank cap Fuel tank capacity: EBU18730 15.0 L (3.96 US gal) (3.30 Imp.gal) Fuel Fuel reserve amount: Make sure that there is sufficient fuel in the tank.

  • Page 36: Fuel Cock

    HOW TO AVOID THE HAZARD Your Yamaha engine has been designed to use Do not overfill the fuel tank. Be careful not to regular unleaded gasoline with a pump octane...
  • Page 37 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 38: Starter (Choke)

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

  • Page 39: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18941 Storage compartment Insert the projections on the front of the seat into The storage compartment is located under the the seat holders and push down on the seat at the seat.

  • Page 40: Front Carrier

    ECB00130 NOTE: CAUTION: There is a check hose at the bottom of the storage Do not store metal or sharply edged objects, compartment. If any water collects in this hose, re- like tools, in the storage compartment. If they move the hose, empty it, and then install it. must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartment.

  • Page 41: Rear Carrier

    Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspen- NOTE: sion, and in direction (b) to decrease the spring A special wrench can be obtained at a Yamaha preload and thereby soften the suspension. dealer to make this adjustment. 4-22...

  • Page 42: Trailer Hitch

    This ATV is equipped with a 5 cm (2 in) trailer hitch 1. Special wrench receiver. Trailer towing equipment can be obtained at a Spring preload setting: Yamaha dealer. (See page 6-7 for precaution in- Minimum (soft): formation.) Standard: Maximum (hard):...

  • Page 43: Auxiliary Dc Jack

    1. Trailer hitch receiver 1. Auxiliary DC jack cap EBU19180 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running.
  • Page 44 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 blow.

  • Page 45: Pre-Operation Checks

    Manual. NOTE: 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. ITEM...
  • Page 46 5-4, 8-26 • Check cooling system for leakage. Correct if necessary. • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-5, 8-38, 8-39, 8-40 •...
  • Page 47 ITEM ROUTINE PAGE Instruments, lights and • Check operation, and correct if necessary. switches...

  • Page 48: Fuel

    EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. Make sure that the final gear oil is at the specified (See page 4-16.) level. Add oil as necessary. (See page 8-21.) EWB00500 WARNING EBU19600 Differential gear oil POTENTIAL HAZARD...

  • Page 49: Front And Rear Brakes

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

  • Page 50: Throttle Lever

    HOW TO AVOID THE HAZARD vided in this manual, have a Yamaha dealer The tires listed below have been approved check for the cause. by Yamaha Motor Manufacturing Corpora- tion of America for this model.

  • Page 51: Measuring The Tire Pressure

    Rear: Tire pressure below the minimum speci- Manufacturer/model: fied could cause the tire to dislodge from MAXXIS/M980 the rim under severe riding conditions. Size: Minimum tire pressure: AT25 x 10-12 Front: Type: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Tubeless Rear: The tires should be set to the recommend- 22.0 kPa (3.2 psi) (0.220 kgf/cm²) ed pressure:...

  • Page 52: Specifications

    Recommended pressure: NOTE: Front The low-pressure tire gauge is included as stan- 25.0 kPa (3.6 psi) (0.250 kgf/cm²) dard equipment. Make two measurements of the Rear tire pressure and use the second reading. Dust or 25.0 kPa (3.6 psi) (0.250 kgf/cm²) dirt in the gauge could cause the first reading to be Minimum: incorrect.

  • Page 53: Chassis Fasteners

    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. Correct if necessary.

  • Page 54: Operation

    Read the Owner’s Manual carefully. If there is prior to operating the engine for the first time. a control or function you do not understand, ask your Yamaha dealer. 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “...
  • Page 55 3. Shift the drive select lever into the neutral or Ambient temp./starter (choke) position park position. The corresponding indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. NOTE: The engine can be started under the following con-...

  • Page 56: Starting A Warm Engine

    If the battery is discharged, pull the recoil starter EBU20291 Starting a warm engine to start the engine. Follow the same procedure as for starting a cold 7. If the engine is started with the starter (choke) engine, with the exception that the starter (choke) in position (1), the starter (choke) should be is not required when the engine is warm.
  • Page 57 The drive select lever cannot be shifted into or from should come on. If the indicator light does not reverse or park without applying the brake pedal. come on, have a Yamaha dealer check the elec- trical circuit. 1. Bring the ATV to a complete stop.

  • Page 58: Engine Break-In

    Due to the synchronizing mechanism in the en- For ATVs not equipped with an odometer or gine, the indicator light may not come on until the hour meter, follow the figures given in hours. ATV starts moving. There is never a more important period in the life of 4.

  • Page 59: Parking

    If any engine trouble should occur during the transversely across the incline, stop the en- engine break-in period, immediately have a Yamaha dealer check the ATV. gine, shift the drive select lever to the park position, and then block the front and rear wheels with rocks or other objects.

  • Page 60: Accessories And Loading

    You must use common sense and good judgment may also be available on the market. However, when carrying cargo or towing a trailer. Keep the it is not possible for Yamaha to test all non- following points in mind: Yamaha accessories, nor control over their qual- Never exceed the weight limits shown.
  • Page 61 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 210.0 kg (463 lb) of the ATV as possible.
  • Page 62 EWB00750 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.

  • Page 63: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 64: Getting To Know Your Atv

    EWB00010 ular attention to the safety information on pages WARNING 1-1–1-5. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. RIDE WITH CARE AND GOOD JUDGEMENT EBU21471 Get training if you are inexperienced.
  • Page 65 Yamaha. They should then ry or death of the child. regularly practice the skills learned in the HOW TO AVOID THE HAZARD course and the operating techniques de- A child under 16 should never operate an scribed in this Owner’s Manual.
  • Page 66 This ATV is designed to carry operator and car- go only – passengers prohibited. EWB00910 WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger.
  • Page 67 Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet EWB00920 WARNING that fits properly. You should also wear: POTENTIAL HAZARD eye protection (goggles or face shield) Operating this ATV without wearing an ap- gloves proved motorcycle helmet, eye protection boots and protective clothing.
  • Page 68 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. by the influence of alcohol or drugs. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.
  • Page 69 EWB00950 Do not operate at speeds too fast for your skills WARNING or the conditions. EWB00960 POTENTIAL HAZARD WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Operating this ATV at speeds too fast for Use of improper tires on this ATV, or opera- your skills or the conditions.
  • Page 70 Speed limiter Loading and accessories For riders less experienced with this model, the Use extra caution when riding the ATV with addi- throttle lever housing is equipped with a speed lim- tional loads, such as accessories or cargo. The iter. The speed limiter keeps the throttle from fully ATV’s handling may be adversely affected.
  • Page 71 EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
  • Page 72 During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op- Removing even one hand or foot can reduce eration, otherwise they may contact the rear your ability to control the ATV or could wheels. cause you to lose your balance and fall off of the ATV.
  • Page 73 Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo- nents designed for use on this ATV and should be installed and used according to instructions.

  • Page 74: Be Careful Where You Ride

    Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system.
  • Page 75 HOW TO AVOID THE HAZARD EWB01030 WARNING Always avoid paved surfaces, including sidewalks, driveways, parking lots and POTENTIAL HAZARD streets. Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one.
  • Page 76 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 77 HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. EWB01060 WARNING POTENTIAL HAZARD...
  • Page 78 Do not ride in areas posted “no trespassing”. be hot when riding and afterwards; do not allow Do not ride on private property without getting per- skin or clothing to come in contact with these com- mission. ponents. With the engine idling, shift the drive select lever into the low-range position or the high-range posi- tion.

  • Page 79: Turning Your Atv

    TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off-road Always follow proper procedures for turning in 2WD or 4WD, the two rear wheels turn together as described in this Owner’s Manual. Prac- at the same speed. Furthermore, when riding in tice turning at low speeds before attempting 4WD-LOCK (“DIFF.

  • Page 80: Climbing Uphill

    As you approach a curve, slow down and begin to may continue to go straight. If the ATV doesn’t turn the handlebars in the desired direction. As you turn, come to a stop and then practice the proce- do so, put your weight on the footboard to the out- dure again.
  • Page 81 oped your skill. In all cases avoid inclines with slip- pery or loose surfaces, or obstacles that might cause you to lose control. EWB01090 WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The ATV can overturn more easily on ex- tremely steep hills than on level surfaces or small hills.
  • Page 82 It is important when climbing a hill to make sure HOW TO AVOID THE HAZARD that your weight is transferred forward on the ATV. Always follow proper procedures for climb- This can be accomplished by leaning forward and, ing hills as described in this Owner’s Manu- on steeper inclines, standing on the footboards and leaning forward over the handlebars.
  • Page 83 7-21...
  • Page 84 If you are climbing a hill and you find that you have When crossing the side of a hill: not properly judged your ability to make it to the Always follow proper procedures as de- top, you should turn the ATV around while you still scribed in the Owner’s Manual.
  • Page 85 If you start to roll backwards, DO NOT apply either If you begin rolling backwards: brake abruptly. If you are in 2WD, apply only the Keep weight uphill. front brake. If you are in 4WD or 4WD-LOCK, be- 2WD: Never apply the rear brake while roll- cause all wheels are interconnected by the drive ing backwards.

  • Page 86: Riding Downhill

    RIDING DOWNHILL Whenever possible, ride your ATV straight down- When riding your ATV downhill, shift your weight hill. Avoid sharp angles which could allow the ATV as far to the rear and uphill side of the ATV as pos- to tip or roll over. Carefully choose your path and sible.
  • Page 87 7-25...

  • Page 88: Crossing A Slope

    CROSSING A SLOPE HOW TO AVOID THE HAZARD Traversing a sloping surface on your ATV requires Never attempt to turn the ATV around on any you to properly position your weight to maintain hill until you have mastered the turning tech- proper balance.
  • Page 89 7-27...

  • Page 90: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
  • Page 91 1. Air filter case check hose ECB00280 CAUTION: After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the storage compartment check hose.

  • Page 92: Riding Over Rough Terrain

    1. V-belt case drain plug 1. Drive select lever box check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident.

  • Page 93: Sliding And Skidding

    WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.

  • Page 94: What To Do If

    If the rear wheels of your ATV start to slide side- EWB01170 WARNING ways, control can usually be regained (if there is room to do so) by steering in the direction of the POTENTIAL HAZARD slide. Applying the brakes or accelerating is not Skidding or sliding improperly.

  • Page 95: What To Do

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

  • Page 96: Periodic Maintenance And Minor Repair

    Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.
  • Page 97 Yamaha ATV dealer. additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

  • Page 98: 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 99 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 100: 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 101 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Drive shaft univer- √ √ √ • Lubricate with lithium-soap-based grease. sal joint • Make sure that all nuts, bolts, and screws are √...
  • Page 102 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 103 Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.

  • Page 104: Removing And Installing Panels

    EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed.
  • Page 105 To install one of the panels 1. Place the panel in its original position. 8-10...
  • Page 106 Panel B To remove the panel Remove the bolt, and then take the panel off. 1. Panel B 2. Bolt To install the panel Place the panel in the original position and install the bolt. ECB00380 CAUTION: When installing the panel, be sure not to pinch 2.
  • Page 107 Panel C To remove the panel 1. Remove the carrier top bolts. 1. Carrier bolt (under the fenders) 3. Remove the quick fastener screws, and then pull the panel upward to remove it. 1. Carrier bolt (top) 2. Remove the carrier bolts under the fenders, and then take the carrier off.
  • Page 108 Panel E To remove the panel Remove the bolts, and then take the panel off. 1. Quick fastener screw 2. Panel C To install the panel 1. Place the panel in the original position, and 1. Panel E then install the quick fastener screws. 2.

  • Page 109: Checking The Spark Plug

    EBU23221 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart.
  • Page 110 Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 111: Engine Oil And Oil Filter Cartridge

    NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4.
  • Page 112 NOTE: If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. 4. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag.
  • Page 113 To change the engine oil (with or without oil fil- NOTE: ter cartridge replacement) Skip steps 6–10 if the oil filter cartridge is not being 1. Remove panel F. (See page 8-9.) replaced. 2. Place the ATV on a level surface. 6.
  • Page 114 1. Oil filter wrench 1. O-ring NOTE: NOTE: An oil filter wrench is available at a nearby Yamaha Make sure that the O-ring is properly seated. dealer. 9. Install the new oil filter cartridge with an oil fil- 8. Apply a thin coat of engine oil to the O-ring of ter wrench, and then tighten it to the specified the new oil filter cartridge.
  • Page 115 12. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.43 US qt) (2.02 Imp.qt) With oil filter cartridge replacement: 2.40 L (2.54 US qt) (2.11 Imp.qt) 1.

  • Page 116: 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 1.
  • Page 117 4. Remove the final gear oil filler bolt and the fi- Tightening torque: nal gear oil drain bolt to drain the oil from the Final gear oil filler bolt: final gear case. 24 Nm (2.4 m·kgf, 17 ft·lbf) To change the final gear oil 1.
  • Page 118 ECB00420 CAUTION: Be sure no foreign material enters the final gear case. 7. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 24 Nm (2.4 m·kgf, 17 ft·lbf) 1. Final gear oil filler bolt 8.

  • Page 119: 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 level must be checked and the oil changed as follows at the in- tervals specified in the periodic maintenance and lubrication chart.
  • Page 120 To change the differential gear oil 5. Add the recommended differential gear oil to 1. Place the ATV on a level surface. the brim of the filler hole as shown. 2. Place an oil pan under the differential gear case to collect the used oil. 3.

  • Page 121: Coolant

    Tightening torque: NOTE: Differential gear oil filler bolt: The coolant should be between the minimum and 23 Nm (2.3 m·kgf, 17 ft·lbf) maximum level marks. 7. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23470 Coolant The coolant level should be checked before each...

  • Page 122: Changing The Coolant

    If water has been added to the coolant, have cap. a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- 1. Place the ATV on a level surface.
  • Page 123 4. Remove the front carrier and panel C. (See page 8-9.) 5. Remove the radiator cap. 1. Coolant drain bolt 1. Radiator cap 6. Remove panel D. (See page 8-9.) 7. Remove the coolant reservoir cap. 8. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the cool- ant reservoir.
  • Page 124 13. Pour the recommended coolant into the radia- tor until it is full. Antifreeze/water mixture ratio: Recommended antifreeze: High-quality ethylene glycol antifreeze con- taining corrosion inhibitors for aluminum en- gines Coolant quantity: Radiator capacity (including all routes): 1.30 L (1.37 US qt) (1.14 Imp.qt) 1.

  • Page 125: Cleaning The Air Filter Element

    16. Start the engine, and then check for coolant leakage. NOTE: If any leakage is found, have a Yamaha dealer check the cooling system. 1. Air filter case check hose 17. Install the panels and the front carrier.
  • Page 126 1. Air filter case cover holder 1. Air filter element 2. Air filter case cover 4. Pull off the lock plate, and then remove the 3. Pull the air filter element out of the air filter sponge material from the air filter element case.
  • Page 127 7. Check the sponge material and replace it if WHAT CAN HAPPEN damaged. Low-flash-point solvents or gasoline can 8. Apply Yamaha foam air filter oil or other qual- catch fire or explode. ity foam air filter oil to the sponge material. 8-32...

  • Page 128: Cleaning The Spark Arrester

    Never operate the engine with the air filter el- NOTE: ement removed. This will allow unfiltered air The sponge material should be wet but not drip- to enter the engine, causing rapid engine ping. wear and possible engine damage. Addition- 9.

  • Page 129: V-Belt Cooling Duct Check Hose

    2. Remove the tailpipe by pulling it out of the Tightening torque: muffler. Tailpipe bolt: 3. Tap the tailpipe lightly, and then use a wire 10 Nm (1.0 m·kgf, 7.2 ft·lbf) brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside EWB01910 of the tailpipe housing.

  • Page 130: 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 131: Adjusting The Engine Idling Speed

    The engine is warm when it quickly responds to the throttle. NOTE: 2. Remove panel D. (See page 8-9.) If the specified idling speed cannot be obtained as 3. Attach the tachometer to the spark plug lead. described above, have a Yamaha dealer make the adjustment. 8-36...

  • Page 132: Adjusting The Throttle Cable Free Play

    (b). must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. 8-37...

  • Page 133: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm es with use, which can result in improper function. (0.04 in), have a Yamaha dealer replace the brake Therefore, the safety system cable should be pads as a set.

  • Page 134: Checking The Brake Fluid Level

    A low brake fluid level may indicate worn the wear indicator reaches the wear limit mark, brake pads and/or brake system leakage. If the have a Yamaha dealer replace the brake friction brake fluid level is low, be sure to check the brake plates as a set.

  • Page 135: Changing The Brake Fluid

    Water will signifi- free play of zero mm (zero in) as shown. If the free cantly lower the boiling point of the fluid and may play is incorrect, have a Yamaha dealer check the result in vapor lock. brake system.

  • Page 136: Adjusting The Brake Pedal And Rear Brake Lever Free Play And Checking The Brake Pedal Position

    Replacement of brake components requires free play, check the rear brake friction plates for professional knowledge. These procedures wear. should be performed by a Yamaha dealer. Adjusting the brake pedal and brake lever free play The brake pedal free play should measure 17.0–...
  • Page 137 1. Brake pedal free play 1. Locknut 2. Brake lever free play adjusting bolt 2. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the final gear case. 1. Brake lever free play 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt.
  • Page 138 1. Brake lever free play adjusting nut 1. Brake pedal free play adjusting nut 2. Brake camshaft lever 3. Push the brake camshaft lever in direction (a) 3. Gap “A” until it stops [apply approximately 50 N (5.0 4. Push the brake camshaft lever in direction (a) kgf, 11.0 lbf) of force], and then turn the brake until it stops [apply approximately 50 N (5.0 pedal free play adjusting nut on the brake ca-...
  • Page 139 (a) to increase the free play, and in direction (b) to decrease it. Checking the brake pedal position The top of the brake pedal should be positioned 75.0–85.0 mm (2.95–3.35 in) above the footboard. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 8-44...

  • Page 140: Axle Boots

    Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24230 Axle boots The axle boots must be checked for damage at the 1.

  • Page 141: Brake Light Switches

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

  • Page 142: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricants: Front brake lever: Silicone grease...

  • Page 143: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel hub bear- NOTE: ings. To access the brake pedal pivot, remove panel B.

  • Page 144: Checking The Stabilizer Bushes

    Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bush- es if necessary. 1. Grease nipple EBU25051...

  • Page 145: Battery

    To charge the battery WHAT CAN HAPPEN Have a Yamaha dealer charge the battery as soon You could be poisoned. You could be se- as possible if it seems to have discharged. Keep in verely burned by the sulfuric acid in battery mind that the battery tends to discharge more electrolyte.
  • Page 146 If you do not have 2. Make sure to properly connect the battery access to a constant-voltage battery charg- leads to the battery terminals. er, have a Yamaha dealer charge your bat- tery. 1. Positive battery lead (red) 2. Negative battery lead (black)

  • Page 147: Replacing A Fuse

    EBU25313 Replacing a fuse 1. Main fuse 2. Spare main fuse 1. Main fuse 2. Fuse box 8-52...
  • Page 148 ECB00640 CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A 1. Headlight fuse Headlight fuse: 2.

  • Page 149: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25470 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 150 3. Remove the headlight bulb holder by pushing 5. Insert a new headlight bulb into the bulb hold- it in and turning it counterclockwise. er by pushing it in. 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. 4.

  • Page 151: Adjusting A Headlight Beam

    ECB00690 1. Headlight beam adjusting screw CAUTION: EBU25620 It is advisable to have a Yamaha dealer make Replacing the tail/brake light bulb this adjustment. If the tail/brake light bulb burns out, replace it as To raise a headlight beam, turn the adjusting follows.
  • Page 152 1. Tail/brake light assembly 1. Tail/brake light assembly 2. Nut 2. Tail/brake light bulb holder 2. Remove the bulb holder (together with the 3. Remove the defective bulb by pushing it in bulb) by turning it counterclockwise. and turning it counterclockwise. 8-57...

  • Page 153: Removing A Wheel

    1. Tail/brake light bulb holder 1. Wheel nut 2. Tail/brake light bulb 2. Elevate the ATV and place a suitable stand 4. Insert a new bulb into the bulb holder, push it under the frame. in, and then turn it clockwise until it stops. 3.
  • Page 154 Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Tapered nut 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques.

  • Page 155: 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 156: 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 157 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 158: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25870 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 159: Storage

    WHAT CAN HAPPEN Long-term Wet brakes may have reduced stopping abil- Before storing your ATV for several months: ity, increasing the chance of an accident. 1. Follow all the instructions in the “Cleaning” HOW TO AVOID THE HAZARD section of this chapter. Test the brakes after washing.
  • Page 160 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 8-50.

  • Page 161: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 10.00 :1 Overall length: Starting system: 1993 mm (78.5 in) Electric and recoil starter Overall width: Lubrication system: 1093 mm (43.0 in) Wet sump Overall height: Engine oil: 1120 mm (44.1 in) Seat height: Type: 830 mm (32.7 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase:...
  • Page 162 2.40 L (2.54 US qt) (2.11 Imp.qt) Manufacturer: Final gear oil: MIKUNI Type: Type x quantity: Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: BSR33 x 1 ACC-SHAFT-LU-00) Spark plug (s): Quantity: Manufacturer/model: 0.50 L (0.53 US qt) (0.44 Imp.qt)
  • Page 163 Chassis: Minimum: Front: Frame type: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Steel tube frame Rear: Caster angle: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) 2.5 ° Maximum: Trail: Front: 8.5 mm (0.33 in) 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Front tire: Rear: Type: 28.0 kPa (4.1 psi) (0.280 kgf/cm²)
  • Page 164 Operation: Bulb voltage, wattage x quantity: Left hand and right foot operation Headlight: 12 V, 30.0/30.0 W × 2 Front suspension: Type: Tail/brake light: 12 V, 5.0/21.0 W × 1 Double wishbone Spring/shock absorber type: Neutral indicator light: Coil spring/oil damper Wheel travel: Reverse indicator light: 160 mm (6.3 in)
  • Page 165 Auxiliary DC jack fuse: 10.0 A Backup fuse: 10.0 A Four-wheel-drive motor fuse: 10.0 A 10-5...

  • Page 166: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 167 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 168: Noise Regulation

    EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ul- timate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 169: Maintenance Record

    EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 170: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 171 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 172: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”...
  • Page 173 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 174 EBU26132 11-9...
  • Page 175 INDEX Accessories and loading ..........6-7 Differential gear lock indicator light ........ 4-3 Accessories, auxiliary jack ........... 4-24 Differential gear oil ..........5-4, 8-24 Air filter element, cleaning ..........8-30 Drive select lever ............4-14 Axle boots ..............8-45 Drive select lever and driving in reverse ......6-3 Drive select lever safety system cable, adjusting ..
  • Page 176 Identification numbers ..........11-1 Rear knuckle pivots, lubricating ........8-49 Indicator lights and warning light ........4-2 Recoil starter ..............4-15 Instruments, lights and switches ........5-9 Reverse indicator light ............ 4-2 Riding your ATV ............. 7-1 Key identification number ..........11-1 Safety information ............
  • Page 177 V-belt case drain plug ..........8-35 V-belt cooling duct check hose ........8-34 Vehicle identification number ........11-1 Warranty, extended ............11-7 Warranty, limited ............11-5 Wheel hub bearings, checking ........8-48 Wheel, installing ............8-58 Wheel, removing ............8-58...
  • Page 180 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN USA 2007.07-2.6×1 CR...

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