Yamaha YFM40FBB Owner's Manual
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Yamaha YFM40FBB Owner's Manual

Yamaha YFM40FBB Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM40FBB
YFM40FBHB
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-25-02
4S1-F8199-15

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Summary of Contents for Yamaha YFM40FBB

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM40FBB YFM40FBHB WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-25-02 4S1-F8199-15...
  • Page 2 EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 3 Congratulations on your purchase of the Yamaha YFM40FBB/YFM40FBHB. This ATV represents the re- sult of many years of 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 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 5 Please check your local riding laws and regulations before operating this ATV. EBU17402 YFM40FBB/YFM40FBHB OWNER’S MANUAL ©2011 by Yamaha Motor Corporation, U.S.A. 1st edition, February 2011 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

  • Page 6: Table Of Contents

    EWB00011 Throttle lever ..........4-10 WARNING Speed limiter ..........4-11 Indicates a hazardous situation which, if not Front brake lever ........4-11 avoided, could result in death or serious injury. Brake pedal and rear brake lever .....4-12 Parking brake ..........4-13 Shift pedal ..........4-13 Reverse knob “REV”...
  • Page 7 Instruments, lights and switches ....5-6 WHAT TO DO..........7-22 OPERATION ..........6-1 PERIODIC MAINTENANCE AND Starting a cold engine ........ 6-1 ADJUSTMENT..........8-1 Starting a warm engine ......6-3 Owner’s manual and tool kit .......8-2 Shifting ............6-3 Periodic maintenance chart for the Operating the reverse knob and driving in emission control system ......8-3 reverse .............
  • Page 8 Checking and lubricating the front and Noise regulation ........11-4 rear brake levers ........8-38 Maintenance record ........11-5 Checking and lubricating the brake and YAMAHA MOTOR CORPORATION, shift pedals ..........8-39 U.S.A. ATV LIMITED WARRANTY ..11-6 Checking the wheel hub bearings .... 8-40 YAMAHA EXTENDED SERVICE Lubricating the drive shaft universal (Y.E.S.) ...........11-8...

  • Page 9: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 5 6 7...
  • Page 10 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. 3.6 psi, (25 kPa) 5ND-F4877-30 3.6 psi, (25 kPa)
  • Page 11 WARNING UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 1P0-F816L-00...
  • Page 12 Certification of Compliance This ATV complies with applicable provisions of ANSI/SVIA 1-2010 and is subject to an approved ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product safety Commission. YAMAHA MOTOR CORPORATION U.S.A. 6555 Katella Avenue, Cypress, California 90630-5101, U.S.A.

  • Page 13: Safety Information

    EBU17431 SAFETY INFORMATION EBU17446 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 14 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 15 speed when climbing a hill. If you stall or roll Always be sure there are no obstacles or people 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 16 EWB00072 Do not run engine outdoors where engine WARNING exhaust can be drawn into a building Avoid Carbon Monoxide Poisoning through openings such as windows and All engine exhaust contains carbon monoxide, doors. a deadly gas. Breathing carbon monoxide can EWB02591 cause headaches, dizziness, drowsiness, nau- WARNING...
  • Page 17 FOR MORE INFORMATION ABOUT ATV SAFE- TY, call the Consumer Products Safety Commis- sion at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.

  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Fuel cock 1. Spark arrester 2. Recoil starter 2. Air filter case 3. Throttle stop screw 3. Engine oil filler cap 4. Fuses 4. Spark plug 5. Battery 5. Oil filter element 6.

  • Page 19: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Parking brake lock plate 3. Starter (choke) 4. Speedometer 5. Reverse knob 6. Auxiliary DC jack 7.

  • Page 20: Instrument And Control Functions

    EBU17725 INSTRUMENT AND CONTROL FUNCTIONS EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU17770 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights, meter lighting and taillight come on 1.

  • Page 21: Indicator Lights And Warning Light

    10 seconds or more. 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. EBU26932 Oil temperature warning light “...

  • Page 22: Speedometer

    ECB00010 NOTICE Due to the synchronizing mechanism in the differ- The engine may overheat if the ATV is over- ential gear case, the light may not come on until loaded. In this case, reduce the load to spec- the ATV starts moving. ification.

  • Page 23: Fuel Gauge

    1. Fuel gauge 1. Reset knob 2. Red line 2. Speedometer 3. Odometer 4. Tripmeter If the ATV runs out of fuel, move the fuel cock lever EBU18050 to the “RES” position. Approximately 4.0 L (1.06 Fuel gauge US gal, 0.88 Imp.gal) of fuel will be remaining in The fuel gauge indicates the amount of fuel in the the tank.

  • Page 24: Handlebar Switches

    EBU18061 EBU18101 Start switch “ ” Handlebar switches Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. EBU18162 Light switch “ /OFF” Set this switch to “ ”...
  • Page 25 EBU28510 EWB00150 Override switch “OVERRIDE” WARNING Always ride at a slow speed when the ATV is in four-wheel-drive differential gear lock, and al- low extra time and distance for maneuvers. All wheels turn at the same speed when the dif- ferential is locked, so it takes more effort to turn the ATV.
  • Page 26 EBU28432 To change from two-wheel drive to four-wheel On-Command four-wheel-drive switch drive, stop the ATV and push the switch in to the “2WD”/“4WD” “4WD” position. The four-wheel-drive indicator EWB00163 light “ ” comes on. WARNING To change from four-wheel drive to two-wheel Always stop the ATV before changing from drive, stop the ATV and push the switch in to the two-wheel drive to four-wheel drive and vice...
  • Page 27 EBU28372 control and have an accident if you cannot On-Command differential gear lock switch make a sharp enough turn for the speed you “4WD”/“LOCK” are traveling. EWB00131 WARNING This ATV is equipped with a switch allowing you to Always stop the ATV before changing from lock the differential gear when in four-wheel drive.
  • Page 28 1. On-Command four-wheel-drive switch “2WD”/“4WD” 1. Differential gear lock lever 2. On-Command differential gear lock switch “4WD”/“LOCK” 2. On-Command four-wheel-drive switch “2WD”/“4WD” To lock the differential gear in four-wheel drive, Stop the ATV, move the differential gear lock lever make sure the On-Command four-wheel-drive to position (a), and then push the differential gear switch is pushed in to the “4WD”...

  • Page 29: Throttle Lever

    and hold the override switch to disable the differ- ential gear lock speed limiter. (See page 4-6 for a detailed explanation of this switch.) EBU18282 Throttle lever Once the engine is running, pushing the throttle le- ver will increase the engine speed. Regulate the speed of the ATV by varying the throttle position.

  • Page 30: Speed Limiter

    Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. EBU18323 Speed limiter Your ATV is equipped with an adjustable speed limiter.

  • Page 31: Brake Pedal And Rear Brake Lever

    1. Front brake lever 1. Brake pedal 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 32: Parking Brake

    EBU18461 Always be sure you have released the park- Parking brake ing brake before you begin to ride. The brake Use the parking brake before starting the engine or could overheat if you ride the ATV without re- after parking the ATV, especially on a slope. Apply leasing the parking brake.

  • Page 33: Reverse Knob "Rev

    1. Reverse knob “REV” 1. Shift pedal EBU27610 EBU18641 Recoil starter Reverse knob “REV” Firmly grasp the handle and pull slightly until en- The reverse knob is used to shift into reverse. See gagement can be felt. Then pull forcefully, being the “Operating the reverse knob and driving in re- careful not to pull the rope all the way out.

  • Page 34: Fuel Tank Cap

    1. Recoil starter 1. Fuel tank cap EWB02370 EBU18731 WARNING Fuel Shift the transmission into the neutral position Make sure there is sufficient gasoline in the tank. and apply the parking brake before starting the EWB02521 engine, otherwise the ATV could start to move WARNING unexpectedly, which could cause an accident.
  • Page 35 of sparks, open flames, or other sources of ig- Recommended fuel: nition such as the pilot lights of water heaters UNLEADED GASOLINE ONLY and clothes dryers. Fuel tank capacity: 2. Do not overfill the fuel tank. When refueling, 15.0 L (3.96 US gal, 3.30 Imp.gal) be sure to insert the pump nozzle into the fuel Fuel reserve amount: tank filler hole.

  • Page 36: Fuel Cock

    Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher.

  • Page 37: Starter (Choke)

    1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.

  • Page 38: Seat

    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. Seat lock lever To install the seat Insert the projections on the front of the seat into 1.

  • Page 39: Storage Compartment

    1. Storage compartment 1. Seat holder 2. Projection Do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment. EBU18902 Do not exceed the maximum load of 210.0 kg Storage compartment (463 lb) for the ATV. ECB00130 NOTICE EBU18962...

  • Page 40: Rear Carrier

    EBU18972 Rear carrier Do not exceed the load limit of 80.0 kg (176 lb) for the rear carrier. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. EBU19183 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV.
  • Page 41 If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine start- ing may become difficult. Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged.

  • Page 42: 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 43 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 5-3, 8-28, 8-29, 8-31 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 44: Fuel

    Front and rear brakes system should be checked by a Yamaha dealer. Brake levers and brake pedal Check that there is no free play in the front brake lever. If there is free play, have a Yamaha dealer check the brake system.

  • Page 45: Throttle Lever

    Check the operation of the throttle lever. It must 25.0 kPa (0.250 kgf/cm², 3.6 psi) open smoothly and spring back to the idle position Minimum tire pressure: when released. Have a Yamaha dealer correct if Front necessary. 22.0 kPa (0.220 kgf/cm², 3.2 psi)
  • Page 46 Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Manufacturing Corporation of America.

  • Page 47: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are ITP/MUD LITE working properly. Correct if necessary. Size: AT25 x 8-12 Type: Tubeless Rear: Manufacturer/model: ITP/MUD LITE Size: AT25 x 10-12 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling,...

  • Page 48: Operation

    4. Shift the transmission into neutral. The neutral EBU19901 indicator light should come on. If the indicator light does not come on, have a Yamaha deal- Read the Owner’s Manual carefully before riding er check the electrical circuit. the ATV. If there is a control or function you do not understand, ask your Yamaha dealer.
  • Page 49 Position (3): be as short as possible to preserve battery ener- Cold engine start with ambient temperature gy. Do not crank the engine more than 10 sec- above 25 °C (80 °F). onds on each attempt. If the battery is discharged, pull the recoil starter Ambient temp./starter (choke) position to start the engine.

  • Page 50: Starting A Warm Engine

    EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. EBU20541 Shifting This ATV has a 5-speed forward and 1-speed re- verse transmission with a centrifugal, automatic...

  • Page 51: Operating The Reverse Knob And Driving In Reverse

    3. Open the throttle gradually. WARNING! Al- could make the wheels stop rotating and lose ways open the throttle gradually. Opening traction. This could cause loss of control, an the throttle abruptly would increase the accident and injury. It could also cause engine chance of an accident.

  • Page 52: Engine Break-In

    If the indicator light does not come on, transmission may be damaged. have a Yamaha dealer check the electrical circuit. 1. Bring the ATV to a complete stop and shift the 4. Check behind you for people or obstacles, transmission into neutral.

  • Page 53: Parking

    1. Parking brake lock plate 320 km (200 mi) or 20 hours and beyond The ATV can now be operated normally. ECB00220 NOTICE If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV.

  • Page 54: Parking On A Slope

    4. Turn the fuel cock to “OFF”. nection to Yamaha manufacture parts and acces- sories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies pro- duce. Therefore, Yamaha can neither endorse nor...
  • Page 55 Yamaha or modifications not specifically recom- bulky object attached to the handlebars which mended by Yamaha, even if sold and installed by could make steering difficult, an accessory that a Yamaha dealer. limits your ability to move around on the seat, or one that limits your view.
  • Page 56 Never exceed the weight limits shown. An over- the weight on the hitch. If you are carrying cargo loaded ATV can be unstable. and towing a trailer, include the tongue weight in the maximum ATV load limit. MAXIMUM LOADING LIMIT Load cargo on the carriers as close to the center ATV loading limit (total weight of rider, cargo, of the ATV as possible.
  • Page 57 EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 6-10...

  • Page 58: Riding Your Atv

    EBU21132 RIDING YOUR ATV...

  • Page 59: Getting To Know Your Atv

    Beginning and inexperienced operators should have read this Owner’s Manual completely and un- complete the certified training course offered by derstand the operation of the controls. Pay partic- Yamaha. They should then regularly practice the skills learned in the course and the operating tech-...
  • Page 60 niques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics.
  • Page 61 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 62 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 63 opening, even when the throttle lever is pushed to Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see “MAXIMUM LOADING the maximum engine power available and de- LIMIT” in this section or vehicle labeling). creases the maximum speed of the ATV.
  • Page 64 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of cargo, rider, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 210.0 kg (463 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
  • Page 65 ATV should be during operation or after leaving the ATV, do not let genuine Yamaha or equivalent components de- brush, grass and other materials collect under the signed for use on this ATV and should be installed vehicle, near the muffler or exhaust pipe, or next to and used according to instructions.

  • Page 66: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for off-road use only. children are not likely to touch it. WARNING! Paved surfaces may seriously af- fect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 67 WARNING! Never operate this ATV on any pub- lic street, road or highway, even a dirt or gravel one. You could collide with another vehicle. [EWB01031] Do not operate on rough, slippery, or loose terrain Know the terrain where you ride. Ride cautiously in until you have learned and practiced the skills nec- unfamiliar areas.
  • Page 68 When riding in an area where you might not easily Do not ride in areas posted “no trespassing”. be seen, such as desert terrain, mount a caution Do not ride on private property without getting per- flag on the ATV. DO NOT use the flag pole bracket mission.

  • Page 69: Turning Your Atv

    Select a large, flat area off-road to become familiar Use this same procedure as you move into the with your ATV. Make sure that this area is free of higher gears. Be sure to coordinate the use of the obstacles and other riders. You should practice throttle and shift pedal properly.
  • Page 70 the ATV will resist turning. A special turning tech- nique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. As you approach a curve, slow down and begin to turn the handlebars in the desired direction.

  • Page 71: Climbing Uphill

    Improper riding procedures such as abrupt throttle Never open the throttle suddenly or make changes, excessive braking, incorrect body move- sudden gear changes. The ATV could flip ments, or too much speed for the sharpness of the over backwards. turn may cause the ATV to tip. If the ATV begins to Never go over the top of any hill at high tip over to the outside while negotiating a turn, lean speed.
  • Page 72 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 73 If you are climbing a hill and you find that you have ATV around and remount, following the procedure not properly judged your ability to make it to the described in the Owner’s Manual. WARNING! top, you should turn the ATV around while you still Stalling, rolling backwards or improperly dis- have forward motion (provided you have the room mounting while climbing a hill could result in...

  • Page 74: Riding Downhill

    RIDING DOWNHILL When riding your ATV downhill, shift your weight EWB01621 as far to the rear and uphill side of the ATV as pos- WARNING sible. Move back on the seat and sit with your arms Going down a hill improperly could cause straight.

  • Page 75: Crossing A Slope

    Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill.

  • Page 76: 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 77: Riding Over Rough Terrain

    ability. WARNING! Wet brakes may have re- duced stopping ability, which could cause loss of control. [EWB02621] 1. Air filter case check hose RIDING OVER ROUGH TERRAIN EWB01651 WARNING After riding your ATV in water, be sure to drain the Riding improperly over obstacles could cause trapped water by removing the check hose at the loss of control or a collision.

  • Page 78: Sliding And Skidding

    cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may re- sult. SLIDING AND SKIDDING EWB01662 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 79: What To Do If

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

  • Page 81: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 82: Owner's Manual And Tool Kit

    1. Owner’s manual additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

  • Page 83: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 85: General Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years •...
  • Page 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and repair or replace if damaged. √ √ √ √ √ 15 * Steering system •...
  • Page 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation. • Check throttle lever free play, and adjust if neces- √ √ √ √ √ Throttle lever sary.

  • Page 89: Checking The Spark Plug

    EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU23213 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- 1.
  • Page 90 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not 1. Spark plug gap attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) 8-10...

  • Page 91: Engine Oil And Oil Filter Element

    To install the spark plug EBU2327E Engine oil and oil filter element 1. Clean the surface of the spark plug gasket The engine oil level should be checked before and its mating surface, and then wipe off any each ride. In addition, the oil must be changed and grime from the spark plug threads.

  • Page 92: Cleaning

    1. Engine oil filler cap 1. Engine oil dipstick 2. Maximum level mark 4. Insert the dipstick into the filler hole (without 3. Minimum level mark screwing it in), and then remove it again to 5. If the engine oil is at or below the minimum check the oil level.
  • Page 93 2. Start the engine, warm it up for several min- utes, and then turn it off. Skip steps 5–9 if the oil filter element is not being 3. Place an oil pan under the engine to collect cleaned. the used oil. 4.
  • Page 94 Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 10. Apply a thin coat of clean engine oil to a new O-ring. 1. O-ring 2. Oil filter element 6. Clean the oil strainer and oil filter element with solvent.

  • Page 95: Final Gear Oil

    Be sure to wipe off spilled oil on any parts after the The final gear case must be checked for oil leak- engine and exhaust system have cooled down. age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- 8-15...
  • Page 96 dition, the final gear oil level must be checked and 3. If the oil is below the brim of the filler hole, add the oil changed as follows at the intervals specified sufficient oil of the recommended type to raise in the periodic maintenance and lubrication chart.
  • Page 97 3. Place an oil pan under the final gear case to 6. Refill with the recommended final gear oil to collect the used oil. the brim of the filler hole as shown. NOTICE: 4. Remove the final gear oil filler bolt, the final Be sure no foreign material enters the final gear oil drain bolt and their O-ring to drain the gear case.

  • Page 98: Differential Gear Oil

    The differential gear case must be checked for oil 3. Differential gear oil leakage before each ride. If any leakage is found, 4. Correct oil level have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil level must be 8-18...
  • Page 99 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 4. Check the gasket for damage, and replace it if necessary. 5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.

  • Page 100: Cleaning The Air Filter Element

    8. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23686 Cleaning the air filter element The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart.
  • Page 101 1. Air filter case cover 1. Air filter case check hose 2. Air filter case cover holder 1. Place the ATV on a level surface. 4. Pull the air filter element assembly out of the 2. Remove the seat. (See page 4-19.) air filter case.
  • Page 102 1. Air filter element assembly 1. Air filter element 2. Sponge material 5. Remove the sponge material from the air filter element. 6. Clean the sponge material with water or sol- vent. WARNING! When using solvent to clean the sponge material, always use parts cleaning solvent or water.
  • Page 103 8. Check the sponge material and replace it if 10. Pull the sponge material over the air filter ele- damaged. ment. 9. Tap the air filter element lightly to remove 11. Insert the air filter element assembly into the most of the dust and dirt. Blow out the remain- air filter case, and then install the air filter case ing dirt with compressed air as shown.

  • Page 104: Cleaning The Spark Arrester

    12. Install the seat. The air filter element should be cleaned every 20– 40 hours. It should be cleaned more often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance is per- formed, check the air inlet of the air filter case for obstructions.

  • Page 105: Adjusting The Carburetor

    5. Install the tailpipe bolts and tighten them to the most carburetor adjustments should be left to a specified torque. Yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment Tightening torque: described in the following section, however, may...

  • Page 106: Adjusting The Engine Idling Speed

    To in- The carburetor has been set and extensively crease the engine idling speed, turn the throt- tested at the Yamaha factory. Changing these tle stop screw in direction (a), and to decrease settings without sufficient technical knowl- it, turn the screw in direction (b).

  • Page 107: Adjusting The Throttle Lever Free Play

    Yamaha dealer at the inter- rection (a). To decrease the throttle lever free vals specified in the periodic maintenance and lu- play, turn the adjusting bolt in direction (b).

  • Page 108: Adjusting The Reverse Lock Release Cable

    If a brake pad is dam- EBU29601 aged or if the lining thickness is less than 1.0 mm Brakes (0.04 in), have a Yamaha dealer replace the brake Replacement of brake components requires pro- pads as a set. fessional knowledge. Brake service should be per- formed by a Yamaha dealer.

  • Page 109: Checking The Brake Fluid Level

    If a brake friction plate has worn to the point that 2. Wear limit mark the wear indicator reaches the wear limit mark, have a Yamaha dealer replace the brake friction EBU29841 plates as a set. Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark.
  • Page 110 If the brake fluid level goes down suddenly, mance. have a Yamaha dealer check the cause before fur- Clean the filler cap before removing. Use ther riding. only DOT 4 brake fluid from a sealed contain-...

  • Page 111: Changing The Brake Fluid

    EBU24281 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are dam- aged or leaking.
  • Page 112 Always perform this maintenance completely in the following order whenever adjusting the rear brake. When adjusting the rear brake, be sure to adjust both the brake pedal and the brake lever. Before adjusting the brake lever and brake pedal free play, check the rear brake friction plates for wear.
  • Page 113 1. Loosen the locknut at the brake lever and fully 2. Fully loosen the brake lever free play adjust- turn in the brake lever free play adjusting bolt. ing nut on the brake cable at the final gear case. 1. Locknut 1.
  • Page 114 3. Push the brake camshaft lever in direction (a) 4. Push the brake camshaft lever in direction (a) until it stops [apply approximately 47 N (4.7 until it stops [apply approximately 47 N (4.7 kgf, 10.6 lbf) of force], and then turn the brake kgf, 10.6 lbf) of force], and then turn the brake pedal free play adjusting nut on the brake ca- lever free play adjusting nut on the brake ca-...

  • Page 115: Axle Boots

    (a) to increase the free play, and in direction damage. If any damage is found, have them re- (b) to decrease it. placed by a Yamaha dealer. 1. Locknut 1. Front axle boot (each side) 2. Brake lever free play adjusting bolt 6.

  • Page 116: Brake Light Switches

    2. Slowly turn the clutch adjusting screw coun- be adjusted as follows, but the other brake light terclockwise until resistance is felt, and then switches should be adjusted by a Yamaha dealer. turn it 1/8 clockwise. Turn the rear brake light switch adjusting nut while holding the brake light switch in place.

  • Page 117: Checking And Lubricating The Cables

    If a cable is damaged or does not move 1. Locknut smoothly, have a Yamaha dealer check or replace 2. Clutch adjusting screw Recommended lubricant: Turning the clutch adjusting screw out decreases...

  • Page 118: Checking And Lubricating The Front And Rear Brake Levers

    EWB02581 Recommended lubricants: WARNING Front brake lever: Inspect cables frequently and replace if dam- Silicone grease aged. Corrosion can result when the cable Rear brake lever: sheaths become damaged, and cables can Lithium-soap-based grease also become frayed or kinked, which could restrict the operation of controls and lead to Front brake lever an accident or injury.

  • Page 119: Checking And Lubricating The Brake And Shift Pedals

    Rear brake lever Brake pedal Shift pedal EBU28841 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease 8-39...

  • Page 120: Checking The Wheel Hub Bearings

    If there is play in a wheel hub or if a wheel does not turn smoothly, Recommended lubricant: have a Yamaha dealer check the wheel hub bear- Lithium-soap-based grease ings. EBU25022...

  • Page 121: Lubricating The Steering Shaft

    1. Grease nipple EBU25092 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. For parts equipped with a grease nipple, use a grease gun.
  • Page 122 EWB02160 To remove the battery WARNING 1. Remove the seat. (See page 4-19.) Battery electrolyte is poisonous and danger- 2. Remove the battery holding plate by removing ous, as it contains sulfuric acid, which can the bolts. cause severe burns. Avoid contact with skin, 3.
  • Page 123 To charge the battery To install the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in Be sure the battery is fully charged. mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- 1.

  • Page 124: Replacing A Fuse

    4. Install the seat. (See page 4-19.) EBU28861 Replacing a fuse 1. Headlight fuse 2. Ignition fuse 3. Auxiliary DC jack fuse 4. Carburetor warmer fuse 1. Main fuse 5. Spare fuse 2. Spare main fuse The main fuse, the four-wheel-drive motor fuse, 3.

  • Page 125: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU28443 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 126 1. Coupler 1. Headlight beam adjusting screw 2. Screw 2. Headlight unit screw 3. Remove the headlight unit from its cover by 4. Remove the headlight bulb holder cover by removing the headlight beam adjusting screw pulling it off. and headlight unit screws. 8-46...
  • Page 127 6. Remove the burnt-out bulb by pulling it out. 7. Insert a new headlight bulb into the bulb hold- er. NOTICE: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.

  • Page 128: Adjusting A Headlight Beam

    ECB00690 NOTICE 1. Open the storage compartment. (See page 4-20.) It is advisable to have a Yamaha dealer make 2. Remove the tail/brake light assembly by re- this adjustment. moving the nuts together with the washers. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a).
  • Page 129 1. Storage compartment 1. Tail/brake light bulb holder 2. Nut 2. Tail/brake light assembly 3. Remove the tail/brake light bulb holder (to- 4. Remove the burnt-out bulb by pushing it in gether with the bulb) by turning it counter- and turning it counterclockwise. clockwise.

  • Page 130: Removing A Wheel

    1. Tail/brake light bulb holder 1. Wheel nut 2. Tail/brake light bulb 3. Elevate the ATV and place a suitable stand 5. Insert a new bulb into the bulb holder, push it under the frame. in, and then turn it clockwise until it stops. 4.
  • Page 131 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 3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified torques.

  • Page 132: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 133: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 134: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25881 tion of wheel bearings, brakes, transmis- Cleaning sion seals and electrical devices. Many Frequent, thorough cleaning of your ATV will not expensive repair bills have resulted from only enhance its appearance but will improve its improper high-pressure detergent applica- general performance and extend the useful life of tions such as those available in coin-oper-...

  • Page 135: Storage

    EBU25933 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inder, piston rings, etc.
  • Page 136 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.

  • Page 137: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Compression ratio: 8.60 : 1 Overall length: Starting system: 2016 mm (79.4 in) Electric and recoil starter Overall width: Lubrication system: 1116 mm (43.9 in) Wet sump Overall height: Engine oil: 1187 mm (46.7 in) Seat height: Recommended brand: 895 mm (35.2 in) YAMALUBE...
  • Page 138 3.00 L (3.17 US qt, 2.64 Imp.qt) 0.6–0.7 mm (0.024–0.028 in) Final gear oil: Clutch: Type: Clutch type: Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: Wet, centrifugal automatic ACC-SHAFT-LU-00) Transmission: Quantity: Primary reduction system: 0.50 L (0.53 US qt, 0.44 Imp.qt)
  • Page 139 Reverse gear: Rear: 22/17 × 35/15 (3.020) 25.0 kPa (0.250 kgf/cm², 3.6 psi) Chassis: Minimum: Front: Frame type: 22.0 kPa (0.220 kgf/cm², 3.2 psi) Steel tube frame Rear: Caster angle: 22.0 kPa (0.220 kgf/cm², 3.2 psi) 4.0 ° Front wheel: Trail: 21.0 mm (0.83 in) Wheel type:...
  • Page 140 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Meter lighting: Double wishbone 12 V, 1.7 W × 1 Spring/shock absorber type: Neutral indicator light: Coil spring/oil damper 12 V, 1.7 W × 1 Wheel travel: Reverse indicator light: 147 mm (5.8 in) 12 V, 1.7 W ×...

  • Page 141: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 142 Model label ment Canada. The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 143 1. Vehicle Emission Control Information label 11-3...

  • Page 144: 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 145: 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 146: 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 147 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 148: 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 149 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 150 INDEX Accessories and loading ..........6-7 Differential gear oil ..........5-3, 8-18 Accessories, auxiliary jack ........... 4-21 Drive shaft universal joint, lubricating ......8-40 Air filter element, cleaning ..........8-20 Axle boots ..............8-35 Engine break-in .............. 6-5 Engine, cold start ............6-1 Battery ................
  • Page 151 Riding your ATV ............. 7-1 Key identification number ..........11-1 Safety information ............2-1 Seat ................4-19 Label locations ............... 1-1 Shifting ................6-3 Light switch ..............4-5 Shift pedal ..............4-13 Spark arrester, cleaning ..........8-24 Main switch ..............4-1 Spark plug, checking .............
  • Page 152 Wheel, installing ............8-50 Wheel, removing ............8-50...
  • Page 153 EBU30390 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect.
  • Page 154 EBU26151 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER ALWAYS operate: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough...

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