Yamaha Grizzly YFM35FGIX Owner's Manual
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Yamaha Grizzly YFM35FGIX Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM35FGIX
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-21-40
4S2-F8199-11

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Summary of Contents for Yamaha Grizzly YFM35FGIX

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35FGIX WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-21-40 4S2-F8199-11...
  • 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 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 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

    Speed limiter ..........4-10 EWB00010 WARNING Front brake lever ........4-11 Brake pedal and rear brake lever .....4-12 Indicates a potential hazard that could result in serious injury or death. Parking brake ..........4-13 Drive select lever ........4-13 Recoil starter ..........4-14 Fuel tank cap ..........4-15 EBU17420 Fuel ............4-15 TABLE OF CONTENTS...
  • Page 7 Tire wear limit ..........5-7 WHAT TO DO IF........7-32 Chassis fasteners ........5-7 WHAT TO DO..........7-32 Instruments, lights and switches ....5-7 PERIODIC MAINTENANCE AND OPERATION ..........6-1 MINOR REPAIR ..........8-1 Starting a cold engine ........ 6-1 Owner’s manual and tool kit .......8-1 Starting a warm engine ......
  • Page 8 ........8-39 Noise regulation ........11-3 Checking and lubricating Maintenance record ........11-4 the brake pedal ........8-40 YAMAHA MOTOR CORPORATION, Checking the wheel hub bearings .... 8-40 U.S.A. ATV LIMITED WARRANTY ..11-5 Lubricating the drive shaft YAMAHA EXTENDED SERVICE universal joint .........

  • Page 9: Safety Information

    EBU17430 SAFETY INFORMATION EBU17542 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 roll backwards, follow the special procedure for Always be sure there are no obstacles or people braking described in this manual. Dismount on behind you when you operate in reverse. When the uphill side or to a side if pointed straight up- 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. WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident.

  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly spring preload adjusting 1. Spark arrester ring 2. Storage compartment and tool kit 2. Fuel cock 3. Air filter case 3. Throttle stop screw 4. Spark plug 4.

  • 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. Parking brake lock plate 5. Drive select lever 6. Speedometer 7.

  • Page 20: Instrument And Control Functions

    EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 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

    NOTE: Indicator lights and warning light If the indicator light flashes under any other circum- stances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. EBU17870 Neutral indicator light “NEUTRAL”...

  • Page 22: Speedometer

    On-Command differential gear lock indicator cool. If the warning light stays on when the engine light “ ” is cool, have a Yamaha dealer check the electrical This indicator light and the On-Command four- circuit. wheel-drive indicator light “ ” come on when the...

  • Page 23: Handlebar Switches

    EBU18061 Handlebar switches 1. Reset knob 2. Speedometer 3. Odometer 1. Light switch “ /OFF” 4. Tripmeter 2. Start switch “ ” 3. Engine stop switch “ ” 4. Override switch “OVERRIDE” EBU18080 Engine stop switch “ ” Set this switch to “ ”...
  • Page 24 EBU18100 EBU28350 Start switch “ ” Override switch “OVERRIDE” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18160 Light switch “ /OFF” Set this switch to “ ”...
  • Page 25 EWB00110 “4WD” (four-wheel drive): Power is supplied to 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 Riding too fast while the ATV is in four- “4WD”...
  • Page 26 EWB00120 EBU28360 On-Command differential gear lock switch WARNING “4WD”/“LOCK” POTENTIAL HAZARD This ATV is equipped with a switch allowing you to Changing from two-wheel drive to four- lock the differential gear when in four-wheel drive. wheel drive or from four-wheel drive to two- Select the appropriate switch position according to wheel drive while the ATV is moving.
  • Page 27 To lock the differential gear in four-wheel drive, make sure the On-Command four-wheel-drive switch is pushed in to the “4WD” position. 1. On-Command differential gear lock switch “4WD”/“LOCK” To release the differential gear lock, stop the ATV and push the switch to the “4WD” position. 1.
  • Page 28 EWB00091 WHAT CAN HAPPEN WARNING All wheels turn at the same speed when the differential gear is locked, so it takes more POTENTIAL HAZARD effort to turn the ATV. The effort needed to Changing from four-wheel drive to four- turn increases with the riding speed. You wheel-drive differential gear lock or vice-ver- may lose control and have an accident if you sa while the ATV is moving.

  • Page 29: Throttle Lever

    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 30: Front Brake Lever

    2. To increase the maximum engine power avail- WHAT CAN HAPPEN able and the maximum speed of the ATV, turn The throttle cable could be damaged. Im- the adjusting screw in direction (a). To de- proper throttle operation could result. You crease the maximum engine power available could lose control, have an accident or be in- and the maximum speed of the ATV, turn the...

  • 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

    EBU18450 WHAT CAN HAPPEN Parking brake The ATV could start moving unexpectedly if Use the parking brake before starting the engine or the parking brake is not applied before start- parking the ATV, especially on a slope. Apply the ing the engine. This could cause loss of con- rear brake lever and push down the lock plate to trol or a collision.

  • Page 33: Recoil Starter

    1. Drive select lever 1. Recoil starter EWB00300 EBU18660 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 shifting into the careful not to pull the rope all the way out. neutral position.

  • Page 34: 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: 1. Fuel tank cap UNLEADED GASOLINE ONLY Fuel tank capacity: EBU18730 13.5 L (3.57 US gal) (2.97 Imp.gal) Fuel Fuel reserve amount: Make sure that there is sufficient fuel in the tank.

  • Page 35: 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 36 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 37: 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 38: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18911 Storage compartment Insert the projections on the front of the seat into ECB00130 the seat holders and push down on the seat at the CAUTION: rear.

  • Page 39: Front Carrier

    1. Storage compartment 1. Storage compartment check hose Do not exceed the load limit of 2.0 kg (4 lb) EBU18960 Front carrier for the storage compartment. Do not exceed the maximum load of 210.0 kg Do not exceed the load limit of 40.0 kg (88 lb) for (463 lb) for the ATV.

  • Page 40: Adjusting The Front And Rear Shock Absorber Assemblies

    Spring preload setting: Minimum (soft): Standard: Maximum (hard): EWB00350 1. Spring preload adjusting ring WARNING 2. Position indicator POTENTIAL HAZARD NOTE: Improper shock absorber assembly adjust- A special wrench can be obtained at a Yamaha ment. dealer to make this adjustment. 4-21...
  • Page 41 WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorber assem- blies on the left and right side to the same setting.

  • Page 42: 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 43 Differential gear oil • Check ATV for oil leakage. Correct if necessary. 5-3, 8-19 • 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, 8-29, 8-30, 8-31 •...

  • Page 44: Fuel

    Check that there is no free play in the front brake HOW TO AVOID THE HAZARD lever. If there is free play, have a Yamaha dealer Do not overfill the fuel tank. Be careful not to check the brake system.

  • Page 45: Throttle Lever

    If a problem cannot be corrected by the adjustment procedures pro- Brake fluid leakage (front brake) vided in this manual, have a Yamaha dealer Check to see if any brake fluid is leaking out of the check for the cause.

  • Page 46: Tires

    HOW TO AVOID THE HAZARD Rear: The tires listed below have been approved 25.0 kPa (3.6 psi) (0.250 kgf/cm²) by Yamaha Motor Manufacturing Corpora- • Check and adjust tire pressures when tion of America for this model. Other tire the tires are cold.

  • Page 47: Specifications

    Tire pressure below the minimum speci- NOTE: fied could cause the tire to dislodge from The low-pressure tire gauge is included as stan- the rim under severe riding conditions. dard equipment. Make two measurements of the Minimum tire pressure: tire pressure and use the second reading. Dust or Front: dirt in the gauge could cause the first reading to be 22.0 kPa (3.2 psi) (0.220 kgf/cm²)

  • Page 48: Tire Wear Limit

    Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Tire wear limit Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) EBU19840 Chassis fasteners Rear...

  • Page 49: 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. Set the parking brake. 2. Turn the fuel cock to “ON”.
  • Page 50 4. Shift the drive select lever into the neutral po- Ambient temp./starter (choke) position sition. The neutral indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical cir- cuit. NOTE: The engine can be started under the following con- ditions: The drive select lever is in the neutral position.

  • Page 51: 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 52 NOTE: When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 1. Drive select lever 2. F (Forward) 3. N (Neutral) 4. R (Reverse) 3.

  • Page 53: Engine Break-In

    If any engine trouble should occur during the your engine than the first 320 km (200 mi) or 20 engine break-in period, immediately have a hours of riding. For this reason, you should read Yamaha dealer check the ATV. the following material carefully.

  • Page 54: Parking

    EBU20700 WHAT CAN HAPPEN Parking The ATV could roll out of control, increasing When parking the ATV, stop the engine, shift the the chance of an accident. drive select lever into the forward position, apply HOW TO AVOID THE HAZARD the parking brake, and then turn the fuel cock to Avoid parking on hills or other inclines.

  • Page 55: Accessories And Loading

    Keep the may also be available on the market. However, following points in mind: it is not possible for Yamaha to test all non- Never exceed the weight limits shown. An over- Yamaha accessories, nor control over their qual-...
  • Page 56 Load cargo on the carriers as close to the center MAXIMUM LOADING LIMIT of the ATV as possible. Put cargo at the rear of ATV loading limit (total weight of rider, cargo, the front carrier, at the front of the rear carrier, accessories, and tongue): and center it.
  • Page 57 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. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo or pull- ing a trailer.

  • Page 58: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 59: 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. EBU28480 GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use.

  • Page 60: Ride With Care And Good Judgement

    Beginners should get training from a certified in- course offered by Yamaha. They should then structor. regularly practice the skills learned in the Become familiar with this ATV at slow speeds first, course and the operating techniques de- even if you are an experienced operator.
  • Page 61 WHAT CAN HAPPEN Use by children of ATVs that are not recom- mended for their age can lead to severe inju- ry or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.
  • Page 62 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 63 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 64 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 65 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 66 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 67 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 68 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 69 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 70: 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 71 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 72 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 73 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 74: Turning Your Atv

    Do not ride in areas posted “no trespassing”. hot when riding and afterwards; do not allow skin Do not ride on private property without getting per- or clothing to come in contact with these compo- mission. nents. With the engine idling, return the starter (choke) to the closed position, shift the drive select lever into the forward position, and then release the parking brake.
  • Page 75 special turning technique must be used to allow This maneuver will let the wheel on the inside of the ATV to make turns quickly and easily. It is es- the turn slip slightly, allowing the ATV to make the sential that this skill be learned first at low speed. turn properly.

  • Page 76: Climbing Uphill

    Once you have learned this technique, you should EWB01090 WARNING be able to perform it at higher speeds or in tighter curves. POTENTIAL HAZARD Improper riding procedures such as abrupt throttle Operating on excessively steep hills. changes, excessive braking, incorrect body move- WHAT CAN HAPPEN ments, or too much speed for the sharpness of the The ATV can overturn more easily on ex-...
  • Page 77 HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing hills as described in this Owner’s Manu- Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly.
  • Page 78 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 79 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 80: 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 81 7-24...

  • Page 82: 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 83 7-26...

  • Page 84: 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 85 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 86: 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 87 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 88: Sliding And Skidding

    SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.

  • Page 89: What To Do If

    WHAT CAN HAPPEN If your ATV begins to tip while turning: You may lose control of this ATV. You may Lean more into the turn to regain balance. If nec- also regain traction unexpectedly, which essary, gradually let off the throttle and/or steer may cause the ATV to overturn.
  • Page 90 If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let wa- ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability.

  • Page 91: 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 92 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 93: 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 94 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 95: 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 96 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 97 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 98 • 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 99: Removing And Installing The Panel

    EWB00010 EBU23111 Panel A WARNING Indicates a potential hazard that could result in To remove the panel serious injury or death. Remove the bolt, and then take the panel off. EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter.

  • Page 100: Checking The Spark Plug

    NOTE: If the spark plug shows a distinctly different color, 1. Spark plug cap the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-10...
  • Page 101 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DR8EA To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

  • Page 102: Engine Oil And Oil Filter Cartridge

    3. Remove the engine oil filler cap, and then NOTE: wipe the dipstick off with a clean rag. If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
  • Page 103 To change the engine oil (with or without oil fil- ter cartridge replacement) 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil.
  • Page 104 5. Remove the oil filter cartridge with an oil filter NOTE: wrench. An oil filter wrench is available at a nearby Yamaha dealer. 6. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
  • Page 105 Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.20 L (2.33 US qt) (1.94 Imp.qt) With oil filter cartridge replacement: 2.30 L (2.43 US qt) (2.02 Imp.qt) NOTE: Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down.

  • Page 106: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified 1.

  • Page 107: To Change Final Gear Oil

    To change the final gear oil 1. Remove the engine guard and the final gear case guard by removing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 1.
  • Page 108 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 109: 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 110 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 111: Cleaning The Air Filter Element

    Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23631 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 112 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 113 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. 8-23...

  • Page 114: 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 115: 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 116: 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 117: Adjusting The Engine Idling Speed

    NOTE: NOTE: If the specified idling speed cannot be obtained as The engine is warm when it quickly responds to the described above, have a Yamaha dealer make the throttle. adjustment. 2. Attach the tachometer to the spark plug lead.

  • Page 118: Adjusting The Throttle Cable Free Play

    The valve clearance changes with use, resulting in bolt in direction (b). improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. 8-28...

  • Page 119: 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 120: 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 121: 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 122: 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 123 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 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.
  • Page 124 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 (5.1 4. Push the brake camshaft lever in direction (a) kgf, 11.2 lbf) of force], and then turn the brake until it stops [apply approximately 50 N (5.1 pedal free play adjusting nut on the brake ca-...
  • Page 125 (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. 8-35...
  • Page 126 Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 1. Distance between brake pedal and footboard EWB02020 WARNING POTENTIAL HAZARD Operating with improperly serviced or ad- justed brakes.

  • Page 127: Axle Boots

    Check the axle boots for tears or damage. If any damage is found, have them re- placed by a Yamaha dealer. 1. Rear axle boot (each side) 1. Front axle boot (each side)

  • Page 128: Brake Light Switches

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

  • Page 129: Checking And Lubricating The Front And Rear Brake Levers

    EWB02120 Recommended lubricants: WARNING Front brake lever: POTENTIAL HAZARD Silicone grease Damaged control cables. Rear brake lever: WHAT CAN HAPPEN Lithium-soap-based grease (all-purpose Corrosion can result when the cable sheaths grease) become damaged, and cables can also be- come frayed or kinked, which could restrict Front brake lever the operation of controls and lead to an acci- dent or injury.

  • Page 130: Checking And Lubricating The Brake Pedal

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

  • Page 131: 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 132: 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 133 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 134: Replacing A Fuse

    EBU25313 Replacing a fuse 1. Headlight fuse 2. Ignition fuse 1. Main fuse 3. Four-wheel-drive motor fuse 2. Spare main fuse 4. Signaling system fuse 3. Fuse box 5. Spare fuse The main fuse and the fuse box are located under the seat.

  • Page 135: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical new fuse of the specified amperage. circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Specified fuses: Yamaha dealer check the electrical system. Main fuse: EBU25470 30.0 A Replacing a headlight bulb Headlight fuse: If a headlight bulb burns out, replace it as follows.
  • Page 136 4. Remove the defective bulb by pulling it out. EWB02180 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and im- mediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable.

  • Page 137: Adjusting A Headlight Beam

    EBU25550 Adjusting a headlight beam ECB00690 CAUTION: 1. Do not touch the glass part of the bulb. It is advisable to have a Yamaha dealer make this adjustment. ECB00650 CAUTION: To raise a headlight beam, turn the adjusting Do not touch the glass part of the headlight screw in direction (a).

  • Page 138: Replacing The Tail/Brake Light Bulb

    Replacing the tail/brake light bulb under the frame. 3. Remove the nuts from the wheel. If the tail/brake light bulb burns out, have a 4. Remove the wheel. Yamaha dealer replace it. EBU25700 EBU25650 Installing a wheel Removing a wheel 1.
  • Page 139 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 140: 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 141: 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 142: 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 143: 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 144 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 8-42.

  • Page 145: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 1995 mm (78.5 in) Electric and recoil starter Overall width: Lubrication system: 1095 mm (43.1 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 146 2.30 L (2.43 US qt) (2.02 Imp.qt) Manufacturer/model: Final gear oil: NGK/DR8EA Type: Spark plug gap: Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: 0.6–0.7 mm (0.024–0.028 in) ACC-SHAFT-LU-00) Clutch: Quantity: Clutch type: 0.50 L (0.53 US qt) (0.44 Imp.qt)
  • Page 147 Front tire: Maximum: Front: Type: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Tubeless Rear: Size: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) AT25 x 8-12 Front wheel: Manufacturer/model: MAXXIS/M979 Wheel type: Rear tire: Panel wheel Rim size: Type: 12 x 6.0AT Tubeless Rear wheel: Size: AT25 x 10-12...
  • Page 148 Spring/shock absorber type: Neutral indicator light: 12 V, 1.7 W × 1 Coil spring/oil damper Wheel travel: Reverse indicator light: 12 V, 1.7 W × 1 160 mm (6.3 in) Rear suspension: Oil temperature warning light: 12 V, 1.7 W × 1 Type: On-command four-wheel-drive indicator light: Double wishbone...

  • Page 149: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 150 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 151: 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 152: 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 153: 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 154 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 155: 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 156 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 157 EBU26132 11-9...
  • Page 158 INDEX Drive select lever ............4-13 Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-7 Drive select lever safety system cable, adjusting ..8-29 Air filter element, cleaning ..........8-21 Drive shaft universal joint, lubricating ......8-40 Axle boots ..............
  • Page 159 Key identification number ..........11-1 Safety information ............1-1 Seat ................4-18 Shock absorber assemblies, Label locations ............... 2-1 adjusting the front and rear ........4-21 Light switch ..............4-5 Spark arrester, cleaning ..........8-24 Spark plug, checking ........... 8-10 Main switch ..............
  • Page 160 Warranty, limited ............11-5 Wheel hub bearings, checking ........8-40 Wheel, installing ............8-48 Wheel, removing ............8-48...
  • Page 162 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 2007.06-2.0×1 CR...

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