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Yamaha GRIZZLY 660 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM660FAT
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-18-03
5KM-28199-13

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  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM660FAT WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-18-03 5KM-28199-13...
  • Page 2 EBU00776...
  • 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 crafts- manship and reliability that have made Yamaha a leader in these fields.

  • Page 4: Warning

    EBU00801 I MPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY 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 WARNING...
  • Page 5 Please check your local riding laws and regulations before operating this ATV. EBU00981 YFM660FAT OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, AFFIX DEALER U.S.A. 1st edition, March 2004 LABEL HERE All rights reserved.

  • Page 6: Table Of Contents

    EBU00014 CONTROL FUNCTIONS....4-1 WARNING Main switch ........4-1 Indicates a potential hazard that could Indicator and warning lights .....4-2 result in serious injury or death. Speedometer unit ......4-4 Handlebar switches ......4-6 Throttle lever ........4-13 CONTENTS Speed limiter ........4-14 Front brake lever......4-15 Brake pedal and rear brake LOCATION OF THE WARNING lever ..........4-15...
  • Page 7 PRE-OPERATION CHECKS ... 5-1 Parking on a slope......6-9 Front and rear brakes ..... 5-3 Accessories and loading ....6-10 Fuel ..........5-5 Engine oil ........5-7 RIDING YOUR ATV ......7-1 Final gear oil........5-7 Getting to know your ATV ....7-3 Differential gear oil ......
  • Page 8 PERIODIC MAINTENANCE AND Checking the rear brake pads ..8-43 ADJUSTMENT........8-1 Checking the brake fluid level..8-44 Owner’s manual and tool kit.... 8-1 Brake fluid replacement ....8-46 Periodic maintenance/ Front brake lever free play.....8-47 lubrication ........8-3 Adjusting the rear brake lever and Panel removal and installation ..
  • Page 9 Troubleshooting charts ....8-63 CLEANING AND STORAGE.... 9-1 A. Cleaning........9-1 B. Storage ........9-3 SPECIFICATIONS......10-1 NOISE REGULATION....11-1 MAINTENANCE RECORD .... 12-1 ATV LIMITED WARRANTY ... 13-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ........... 14-1...

  • Page 10: Location Of The Warning And Specification Labels

    EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 11 NEVER sit here. 3MX-24875-A0 Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. LOAD LIMIT 85 kg {187 lbs} 4WV-24877-A0 MAXIMUM LOADING LIMIT...
  • Page 13 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. 5FE-21697-01 WARNING Turning the ATV in 4WD-LOCK(“DIFF. LOCK”) takes more effort. Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control.

  • Page 14: Safety Information

    EBU01129 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.
  • Page 15 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions.
  • Page 16 Always follow proper procedures for climbing hills as described in this manual. Check the ter- rain 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. Never go over the top of a hill at high speed.
  • Page 17 Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when op- erating over obstacles as described in this manual. Always be careful when skidding or sliding. Learn to safely control skidding or sliding by prac- ticing at low speeds and on level, smooth terrain.
  • Page 18 WARNING When transporting the ATV in another vehicle, be sure it is kept upright and POTENTIAL HAZARD that the fuel cock is in the “OFF” posi- Improper handling of gasoline. tion. Otherwise, fuel may leak out of the WHAT CAN HAPPEN carburetor or fuel tank.
  • Page 19 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. 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 adequate ventilation.

  • Page 20: Description And Machine Identification

    EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Rear shock absorber spring 15. Engine oil dipstick preload adjusting ring 16. Recoil starter 2. Storage compartment and tool kit 17. Coolant reservoir 3. Air filter case 18. Drive select lever box check hose 4.

  • Page 21: Identification Number Records

    This number can be used for ordering a new when ordering spare parts from a Yamaha key. dealer or for reference in case the vehicle is stolen.

  • Page 22: Vehicle Identification Number

    Record the information on this la- bel in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to 1.

  • Page 23: Control Functions

    EBU00039 CONTROL FUNCTIONS WARNING Indicates a potential hazard that could result in serious injury or death. EBU00942 Main switch Functions of the respective switch positions are as follows: 1. Main switch The engine can be started only at this position and the headlights and taillight come on when the light switch is on.

  • Page 24: Indicator And Warning Lights

    EBU00802 EBU10601 Indicator and warning lights Differential gear lock indicator light “DIFF. LOCK” This indicator light and the differential gear lock indicator in the display come on when the differential gear lock switch is set to the “4WD-LOCK” position. NOTE: When the switch is set to “LOCK”, the differ- ential gear lock indicator light will flash until the differential gear is locked.
  • Page 25 If the indicator light flashes or the speedome- differential gear case, the four-wheel drive in- ter does not show the speed while riding, dicator may not come on until the ATV starts have a Yamaha dealer check the speed sen- moving. sor circuit. EBU00609 Park indicator light “P”...

  • Page 26: Speedometer Unit

    EBU00860 EBU15100 Coolant temperature warning light “ ” Speedometer unit When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the en- gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.
  • Page 27 a clock Clock mode an hour meter (which shows the total time Pushing the “ ”/“ ” button switches the the key has been turned to “ON”) display between the clock mode “CLOCK” a fuel meter and the hour meter mode “HOUR” in the fol- lowing order: Odometer and tripmeter modes CLOCK→HOUR→CLOCK...

  • Page 28: Handlebar Switches

    EBU00053 Fuel meter Handlebar switches The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear towards “E” (Empty) as the fuel level decreases. When the “E” segment disappears and the fuel level warning indica- tor flashes, set the fuel cock to reserve and re- fuel as soon as possible.
  • Page 29 EBU12050 Engine stop switch “ ” CAUTION: Make sure that the engine stop switch is set to Do not use the headlights with the engine “ ” before starting the engine. The engine turned off for more than thirty minutes. stop switch controls ignition and can be used The battery may discharge to the point at all times to stop the engine, especially in an...
  • Page 30 In this case, take the ATV to a hold this switch to override the 4WD-LOCK Yamaha dealer at the first opportunity. speed limiting function. (See page 4-11 for a detailed explanation about the differential gear lock switch and its function.) Releasing...
  • Page 31 WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The amount of effort is more the faster you go. You 1.
  • Page 32 Four-wheel drive (4WD): Power is supplied WARNING to the rear and front wheels. POTENTIAL HAZARD Four-wheel drive with the differential gear Changing from 2WD to 4WD or from locked (4WD-LOCK): Power is supplied to 4WD to 4WD-LOCK (“DIFF.LOCK”), or the rear and front wheels when the differen- vice-versa while the ATV is moving.
  • Page 33 1. Lever 1. Differential gear lock switch “LOCK”/“4WD” 2. On-Command four-wheel drive switch “2WD”/“4WD” 2. Lever On-Command four-wheel drive switch Differential gear lock switch “LOCK”/ “2WD”/“4WD” “4WD” To change from 2WD to 4WD, stop the ATV, To lock the differential gear in 4WD, make sure the On-Command four-wheel-drive switch is and then set the switch to “4WD”.
  • Page 34 NOTE: WARNING When the switch is set to “LOCK”, the dif- POTENTIAL HAZARD ferential gear lock indicator light will flash Riding too fast while the ATV is in until the differential gear is locked. 4WD-LOCK. When the indicator light is flashing, turn- WHAT CAN HAPPEN ing the handlebar back and forth will help All wheels turn at the same speed when...

  • Page 35: Throttle Lever

    Check the operation of the throttle lever before 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 1. Throttle lever can’t find or solve the problem yourself. 4-13...

  • Page 36: Speed Limiter

    EBU11590 Speed limiter WARNING The speed limiter keeps the throttle from fully POTENTIAL HAZARD opening, even when the throttle lever is Improper adjustment of the speed limit- pushed to the maximum. Turning in the ad- er and throttle. justing screw limits the maximum engine pow- WHAT CAN HAPPEN er available and decreases the maximum The throttle cable could be damaged.

  • Page 37: Front Brake Lever

    EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to ap- ply the front brake. 1. Brake pedal 1. Front brake lever EBU00732 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar.

  • Page 38: Drive Select Lever

    EBU00608 EBU00855 Drive select lever Recoil starter The drive select lever is used to shift your ma- Firmly grasp the handle and pull slightly until chine into the low, high, neutral, reverse and engagement can be felt. Then pull forcefully, park positions.

  • Page 39: Fuel Tank Cap

    EBU00092 Fuel tank cap WARNING Remove the fuel tank cap by turning it coun- POTENTIAL HAZARD terclockwise. Starting the engine without setting the drive select lever to the park position “P”. WHAT CAN HAPPEN The ATV could start to move unexpect- edly, which could cause an accident.

  • Page 40: Fuel Cock

    EBU00093 Fuel cock OFF Position The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running.

  • Page 41: Starter (Choke)

    EBU00095 Starter (choke) “ ” RES Position Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke).

  • Page 42: Seat

    EBU00567 Seat To install the seat, insert the projections on To remove the seat, pull the seat lock lever the front of the seat into the seat holders and upward and pull up the seat at the rear. push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted.

  • Page 43: Storage Compartment

    EBU00858 EBU00582 Storage compartment Front carrier The storage compartment is located under Maximum load limit: 45 kg (99 lb) the seat. (See page 4-20 for seat removal and installation procedures.) When storing the owner’s manual or other EBU00583 documents in the storage compartment, be Rear carrier sure to wrap them in a plastic bag so that they Maximum load limit: 85 kg (187 lb)

  • Page 44: Front And Rear Shock Absorber Adjustment

    NOTE: justing ring in direction a. A special wrench can be obtained at a To decrease the spring preload, turn the ad- Yamaha dealer to make this adjustment. justing ring in direction b. Standard position: B A- Minimum (soft) E- Maximum (hard)
  • Page 45 WARNING POTENTIAL HAZARD Improper shock absorber adjustment. 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 absorbers on 1. Special wrench the left and right side to the same set- ting.

  • Page 46: Auxiliary Dc Jack

    EBU01002 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1.
  • Page 47 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: Do not use accessories requiring more than the above maximum capac- ity. This may overload the circuit and cause the fuse to blow. If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may be-...

  • Page 48: Pre-Operation Checks

    PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE • Check operation, free play, fluid level and fluid leakage. 5-3–5-4, Brakes • Fill with DOT 4 brake fluid if necessary. 8-43–8-50 • Check fuel level. Fuel 5-5–5-6 •...
  • Page 49 WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op- erating condition.

  • Page 50: Front And Rear Brakes

    If not, have a Yamaha (See page 8-43.) dealer inspect the brake system.
  • Page 51 Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the ad- justment procedures provided in this manual, have a Yamaha dealer check for the cause.

  • Page 52: Fuel

    Yamaha because it may cause fuel system and piston rings, as well as to the exhaust damage or vehicle performance problems.
  • Page 53 WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. 1.

  • Page 54: Engine Oil

    EBU10842 EBU00493 Engine oil Final gear oil Make sure the engine oil is at the specified Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-15– level. Add oil as necessary. (See pages 8-21– 8-20.) 8-22 for details.) CAUTION:...

  • Page 55: Differential Gear Oil

    EBU00678 Differential gear oil Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-23–8-25 for details.) Recommended oil: SAE 80 API GL-4 Hypoid gear oil...

  • Page 56: Coolant

    EBU12530 Coolant WARNING Check the coolant level in the coolant reser- POTENTIAL HAZARD voir when the engine is cold. (The coolant lev- Removing the radiator cap when the en- el will vary with engine temperature.) The gine and radiator are still hot. coolant level is satisfactory if it is between the WHAT CAN HAPPEN minimum and maximum level marks on the...

  • Page 57: Throttle Lever

    EBU11620 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. EBU10030 Lights Check the headlights and tail/brake light to make sure they are in working condition.

  • Page 58: Tires

    HOW TO AVOID THE HAZARD riding conditions. 1. The tires listed below have been ap- The following are minimums: proved by Yamaha Motor Co., Ltd. Front 32 kPa (0.32 kgf/cm , 4.6 psi) for this model. Other tire combina- Rear 27 kPa (0.27 kgf/cm , 3.9 psi)
  • Page 59 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm , 36 psi) Rear 250 kPa (2.5 kgf/cm , 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully.

  • Page 60: How To Measure Tire Pressure

    EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measure- ments of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.

  • Page 61: Tire Wear Limit

    EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit 5-14...

  • Page 62: Operation

    3. Turn the main switch to “ON” and the en- there is a control or function you do not gine stop switch to “ ”. understand, ask your Yamaha dealer. 4. Shift the drive select lever into the neutral or park position.
  • Page 63 25 °C (80 °F) and warm engine does not come on, ask a Yamaha dealer start position. to inspect the respective electric circuit. The engine can be started in any gear if the rear brake lever or brake pedal is ap- plied.

  • Page 64: Starting A Warm Engine

    NOTE: CAUTION: If the engine fails to start, release the See the “Engine break-in” section prior to start switch, then push the start switch operating the engine for the first time. again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery en- EBU00180 ergy.

  • Page 65: Drive Select Lever Operation And Reverse Driving

    EBU08461 Drive select lever operation and reverse driving CAUTION: Before shifting, you must stop the ATV and return the throttle lever to the closed position, otherwise the transmission may be damaged. Shifting: Neutral to High and High to Low 1. Bring the ATV to a complete stop and re- 1.
  • Page 66 If the light does not the drive select lever along the shift come on, ask a Yamaha dealer to inspect guide. the electrical circuit. Due to the synchronizing mechanism in the engine, the light may not come on un- til the ATV starts moving.
  • Page 67 5. Open the throttle lever gradually and con- tinue to watch to the rear while backing. WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person be- hind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind...

  • Page 68: Engine Break-In

    If any abnormality is noticed the following material. Because the engine is during this period, consult a Yamaha dealer. brand new, you must not put an excessive load on it for the first several hours of running.

  • Page 69: Parking

    EBU00612 10–20 hours: Parking Avoid prolonged operation above 3/4 throttle. When parking, stop the engine and shift the Rev the machine freely but do not use full drive select lever into the park position, then throttle at any time. turn the fuel cock to the “OFF” position. After break-in: Avoid prolonged full throttle operation.

  • Page 70: Parking On A Slope

    EBU06151 Parking on a slope 1. Bring the machine to a stop by applying the brakes. WARNING 2. Stop the engine. POTENTIAL HAZARD 3. With the brake pedal applied, shift the Parking on a hill or other incline. drive select lever to the park position “P”. WHAT CAN HAPPEN The ATV could roll out of control, in- creasing the chance of an accident.

  • Page 71: Accessories And Loading

    Choose only accessories designed for your dlebars which could make steering difficult, ATV. Your Yamaha dealer has a variety of an accessory that limits your ability to move genuine Yamaha accessories. Other ac-...
  • Page 72 EBU09601 Loading Do not exceed the maximum tongue Cargo or a trailer can change the stability and weight. You can measure tongue weight handling of an ATV. You must use common with a bathroom scale. Put the tongue of sense and good judgment when carrying car- the loaded trailer on the scale with the go or towing a trailer.
  • Page 73 Ride more slowly than you would without a WARNING load. The more weight you carry, the slow- POTENTIAL HAZARD er you should go. Although conditions vary, Overloading this ATV or carrying or tow- it is good practice not to exceed low range ing cargo improperly.
  • Page 74 EBU15121 WARNING Indicates a potential hazard that could result in serious injury or death. 6-13...

  • Page 75: Riding Your Atv

    R iding Your...

  • Page 76: Getting To Know Your Atv

    WARNING Indicates a potential hazard that could result in serious injury or death. ride, be sure you have read this Owner’s Man- GETTING TO KNOW YOUR ATV ual completely and understand the operation of This ATV is mainly for utility use, but may also the controls.

  • Page 77: Ride With Care And Good Judgement

    JUDGEMENT Beginning and inexperienced operators should complete the certified training Get training if you are inexperienced. course offered by Yamaha. They should Beginners should get training from a certified then regularly practice the skills learned instructor. in the course and the operating tech- Become familiar with this ATV at slow speeds niques described in this Owner’s Manu-...
  • Page 78 Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommenda- tions for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended for their age can lead to se- vere injury or death of the child.
  • Page 79 This ATV is designed to carry operator and cargo only - passengers prohibited. 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 passenger.
  • Page 80 Apparel Operating without protective clothing WARNING increases your chances of severe injury in the event of an accident. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an Always wear an approved motorcycle approved motorcycle helmet, eye pro- helmet that fits properly.
  • Page 81 Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator’s performance capability is reduced Operating this ATV after consuming al- by the influence of alcohol or drugs. cohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly.
  • Page 82 Pre-operation checks WARNING Always perform the pre-operation checks list- POTENTIAL HAZARD ed on page 5-1 before riding for safety and Operating this ATV with improper tires, proper care of the ATV. or with improper or uneven tire pres- WARNING sure. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before oper-...
  • Page 83 Speed limiter WARNING For riders less experienced with this model, Indicates a potential hazard that could this model is equipped with a speed limiter in result in serious injury or death. the throttle lever housing. The speed limiter keeps the throttle from fully opening, even Do not operate at speeds too fast for your when the throttle lever is pushed to the maxi- skills or the conditions.
  • Page 84 Loading and accessories WARNING Use extra caution when riding the ATV with POTENTIAL HAZARD additional loads, such as accessories or car- Overloading this ATV or carrying or tow- go. The ATV’s handling may be adversely af- ing cargo improperly. fected. Reduce your speed when adding WHAT CAN HAPPEN additional loads.
  • Page 85 During operation WARNING Always keep your feet on the footboards dur- POTENTIAL HAZARD ing operation. Otherwise your feet may con- Removing hands from handlebars or tact the rear wheels. feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re- duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
  • Page 86 Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, in- cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.
  • Page 87 Never modify this ATV through improp- er installation or use of accessories. All parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized ATV dealer.
  • Page 88 Exhaust system Do not touch the hot exhaust system. The exhaust system on the ATV is very hot Do not park the ATV in a place where during and following operation. To prevent others might be likely to touch it. burns, avoid touching the exhaust system.

  • Page 89: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of con-...
  • Page 90 Do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD 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...
  • Page 91 Know the terrain where you ride. Ride cau- tiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and oth- er hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 92 WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an acci- dent, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills neces-...
  • Page 93 When riding in an area where you might not WHAT CAN HAPPEN easily be seen, such as desert terrain, mount You could be in a collision. You could a caution flag on the ATV. DO NOT use the be injured. flag pole bracket as a trailer hitch.
  • Page 94 Select a large, flat area off-road to become fa- With the engine idling, shift the drive select le- miliar with your ATV. Make sure that this area ver to the low position “L” or the high position is free of obstacles and other riders. You “H”.

  • Page 95: Turning Your Atv

    TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for road in 2WD or 4WD, the two rear wheels are turning as described in this Owner’s mounted solidly on one axle and turn together Manual.
  • Page 96 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip.

  • Page 97: Climbing Uphill

    CLIMBING UPHILL HOW TO AVOID THE HAZARD Use proper riding techniques to avoid vehicle Never operate the ATV on hills too steep overturns on hills. Be sure that you can ma- for the ATV or for your abilities. Practice neuver your ATV well on flat ground before at- on smaller hills before attempting large tempting any incline and then practice riding hills.
  • Page 98 WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other POTENTIAL HAZARD side of the hill. Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Own- er’s Manual.
  • Page 99 If you are climbing a hill and you find that you WARNING have not properly judged your ability to make POTENTIAL HAZARD it to the top, you should turn the ATV around Improperly crossing hills or turning on while you still have forward motion (provided hills.
  • Page 100 When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. 7-27...
  • Page 101 If your ATV has stalled or stopped and you the front and rear brakes gradually, or dis- believe you can continue up the hill, restart mount the ATV immediately on the uphill side. carefully to make sure you do not lift the front WARNING wheels which could cause you to lose control.
  • Page 102 If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. 4WD or 4WD-LOCK: Apply both front and rear brakes gradually. When fully stopped, shift to the park- ing position “P”. Dismount on uphill side or to a side if pointed straight uphill.

  • Page 103: Riding Downhill

    RIDING DOWNHILL When this ATV is in 4WD or 4WD-LOCK, all When riding your ATV downhill, shift your wheels (front and rear) are interconnected by weight as far to the rear and uphill side of the the drive train. This means that applying either ATV as possible.
  • Page 104 WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for go- ing down hills as described in this Own- er’s Manual. Note: a special technique is required when braking as you go down a hill.

  • Page 105: Crossing A Slope

    CROSSING A SLOPE WARNING Traversing a sloping surface on your ATV re- POTENTIAL HAZARD quires you to properly position your weight to Improperly crossing hills or turning on maintain proper balance. Be sure that you hills. have learned the basic riding skills on flat WHAT CAN HAPPEN ground before attempting to cross a sloping Could cause loss of control or cause the...
  • Page 106 7-33...

  • Page 107: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have re- The ATV can be used to cross slow moving, duced stopping ability. Test your brakes shallow water of up to a maximum of 35 cm after leaving water. If necessary, apply (14 inches) in depth.
  • Page 108 Test your brakes after leaving the water. Do CAUTION: not continue to ride your ATV without verifying After riding your ATV in water, be sure to that you have regained proper braking ability. drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose and the drive select lever box check hose.
  • Page 109 1. V-belt cooling duct check hose (Left side) 1. Drive select lever box check hose 1. V-belt case drain plug 7-36...

  • Page 110: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could Improperly operating over obstacles. cause damage to the ATV or could lead to an WHAT CAN HAPPEN upset or accident. Be sure to keep your feet Could cause loss of control or a colli- firmly mounted on the footboards at all times.

  • Page 111: Sliding And Skidding

    SLIDING AND SKIDDING If the rear wheels of your ATV start to slide Care should be used when riding on loose or sideways, control can usually be regained (if slippery surfaces since the ATV may slide. If there is room to do so) by steering in the direc- unexpected and uncorrected, sliding could tion of the slide.
  • Page 112 With practice, over a period of time, skill at WARNING controlled sliding can be developed. The ter- POTENTIAL HAZARD rain should be chosen carefully before at- Skidding or sliding improperly. tempting such maneuvers, since both stability WHAT CAN HAPPEN and control are reduced. Bear in mind that You may lose control of this ATV.

  • Page 113: What To Do If

    WHAT TO DO IF ... If your ATV starts to slide sideways: This section is designed to be a reference Steer in the direction of the slide if you have guide only. Be sure to read each section on the room. Applying the brakes or accelerat- riding techniques completely.
  • Page 114 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to main- tain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 115: Periodic Maintenance And Adjustment

    EBU00515 PERIODIC MAINTENANCE AND Have a Yamaha dealer perform service if ADJUSTMENT you are not familiar with machine service. Periodic inspection, adjustment and lubrica- tion will keep your machine in the safest and EBU00562 most efficient condition possible. Safety is an Owner’s manual and tool kit...
  • Page 116 HOW TO AVOID THE HAZARD during a service operation requiring one, take Never modify this ATV through improp- your machine to a Yamaha dealer to check er installation or use of accessories. All the torque settings and adjust them as neces- parts and accessories added to this ve- sary.

  • Page 117: Periodic Maintenance/Lubrication

    EBU02611 PERIODIC MAINTENANCE/LUBRICATION NOTE: For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. How- ever, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
  • Page 118 INITIAL EVERY month Whichever ITEM ROUTINE comes first 1,200 2,400 2,400 4,800 (mi) (200) (750) (1,500) (1,500) (3,000) hours • Check fuel hose for cracks or damage. Fuel line* • Replace if necessary. Engine oil • Replace (Warm engine before draining). Engine oil filter cartridge •...
  • Page 119 • Correct if necessary. • Check operation. Lights and switches* • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: •...

  • Page 120: Panel Removal And Installation

    EBU00614 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled. 1. Panel D 2. Panel E 3.
  • Page 121 EBU00879 Panels A and D To remove 1. Remove the seat. (See page 4-20 for seat removal and installation proce- dures.) 2. Pull outward on the area shown, and then pull upward as shown. 1. Panel D 1. Panel A...
  • Page 122 To install 1. Insert the panel projections in the numer- ical order shown in the illustration, and then push inward on the area shown. 2. Install the seat. 1. Panel D 1. Panel A...
  • Page 123 EBU00962 Panel B CAUTION: To remove When installing the panel, be sure not to Remove the bolts. pinch the cables or wires. To install Place the panel in the original position and in- stall the bolts. 1. Panel B 2. Bolt (× 2)
  • Page 124 EBU01141 Panel C To remove 1. Remove the front carrier by removing the stay covers at the rear, then by removing the bolts. 1. Bolt (× 2) (top) 1. Front carrier stay cover (× 2) 1. Bolt (× 2) (top) 8-10...
  • Page 125 To install 1. Place the panel in the original position and install the quick fasteners. 2. Install the front carrier by installing the bolts and tightening them to the specified torques. Tightening torques: Carrier bolt (top): 26 Nm (2.6 m·kgf, 19 ft·lbf) 1.
  • Page 126 EBU01013 Panel E To remove Remove the bolts, and then take the panel off. To install Place the panel in the original position, and then install the bolts. 1. Panel E 2. Bolt (× 6) 8-12...
  • Page 127 EBU00638 Panel F To install To remove Place the panel in its original position. Pull outward on the areas shown. 1. Panel F 8-13...
  • Page 128 EBU15041 Panel G To remove 1. Remove the seat. (See page 4-20 for seat removal and installation proce- dures.) 2. Remove the rear carrier by removing the bolts. 1. Bolt (× 2) (Under fenders) 3. Remove the seat under bracket and the panel by pulling them off.

  • Page 129: Engine Oil And Oil Filter Cartridge

    EBU10992 To install Engine oil and oil filter cartridge 1. Place the panel and the seat under The engine oil level should be checked before bracket in the original position. each ride. In addition, the oil must be changed 2. Install the rear carrier by installing the and the oil filter cartridge replaced at the inter- bolts and tightening them to the specified vals specified in the periodic maintenance...
  • Page 130 5. Remove the engine oil filler cap and wipe 6. Insert the dipstick in the oil filler hole off the dipstick with a clean rag. (without screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the mini- mum and maximum level marks.
  • Page 131 7. If the engine oil is at or below the mini- To change the engine oil (with or without oil filter cartridge replacement) mum level mark, add sufficient oil of the recommended type to raise it to the cor- 1. Remove panel F. (See page 8-13 for rect level.
  • Page 132 8-7–8-8 and 8-12 for panel remov- al and installation procedures.) 6. Remove the oil filter cartridge with an oil filter wrench. 1. O-ring 1. Engine oil filter cartridge 2. Oil filter wrench NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 8-18...
  • Page 133 8. Install the new oil filter cartridge with an 9. Install panels D and E. oil filter wrench, and then tighten it to the 10. Install the engine oil drain bolt, and then specified torque with a torque wrench. tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 30 Nm (3.0 m·kgf, 22 ft·lbf)
  • Page 134 CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a high- er quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II”...

  • Page 135: Final Gear Oil

    Final gear oil The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and re- pair the ATV. Replacing the final gear oil 1. Place the ATV on a level surface.
  • Page 136 Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.25 L (0.22 Imp qt, 0.26 US qt) CAUTION: Be sure no foreign material enters the final gear case. 6. Install the filler bolt and tighten it to the specified torque.

  • Page 137: Differential Gear Oil

    EBU07062 Differential gear oil CAUTION: Differential gear oil measurement Be sure no foreign material enters the dif- 1. Place the ATV on a level surface. ferential gear case. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to 3.
  • Page 138 Differential gear oil replacement 4. Install the differential gear oil drain bolt 1. Place the ATV on a level surface. and tighten it to the specified torque. 2. Place a container under the differential Tightening torque: gear case to collect the used oil. Differential gear oil drain bolt: 3.

  • Page 139: Cooling System

    EBU12560 Cooling system Tightening torque: 1. Place the ATV on a level surface. Differential gear oil filler bolt: 2. Check the coolant level in the coolant 23 Nm (2.3 m·kgf, 16 ft·lbf) reservoir when the engine is cold as the coolant level will vary with engine tem- 7.
  • Page 140 NOTE: 3. If the coolant is at or below the minimum If water is added, have a Yamaha dealer level mark, remove panel D (See check the antifreeze content of the cool- pages 8-7–8-8 for panel removal and in- ant as soon as possible.
  • Page 141 EBU12572 Changing the coolant 1. Place the ATV on a level surface. 2. Remove panels (See WARNING pages 8-12–8-13 for panel removal and POTENTIAL HAZARD installation procedures.) Removing the radiator cap when the en- 3. Place a container under the engine, and gine and radiator are still hot.
  • Page 142 1. Trough 1. Radiator cap 4. Remove the front carrier and panel C. 5. Remove the radiator cap. (See pages 8-10 and 8-11 for removal 6. Remove panel D. (See pages 8-7–8-8 for and installation procedures.) panel removal and installation proce- dures.) 7.
  • Page 143 11. Install the coolant reservoir hose. 12. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap and panel D. 13. Pour the recommended coolant into the radiator until it is full, and then install the radiator cap.
  • Page 144 15. Check for coolant leakage. NOTE: If any leakage is found, have a Yamaha deal- er check the cooling system. 16. Install the panels and the front carrier. 8-30...

  • Page 145: Axle Boots

    EBU00862 Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. 1. Rear axle boot (× 2 each side) 1. Front axle boot (× 2 each side) 8-31...

  • Page 146: Spark Plug Inspection

    EBU00864 Spark plug inspection Removal 1. Remove panel A. (See pages 8-7–8-8 for panel removal and installation proce- dures.) 2. Remove the spark plug cap. 1. Spark plug wrench 1. Spark plug cap 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown.
  • Page 147 ATV that is being ridden normally. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically re- move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

  • Page 148: Air Filter Element Cleaning

    EBU12111 Air filter element cleaning Tightening torque: NOTE: Spark plug: There is a check hose at the bottom of the air 17.5 Nm (1.75 m·kgf, 12.5 ft·lbf) filter case. If dust or water collects in this hose, empty the hose and clean the air filter NOTE: If a torque wrench is not available when you element and air filter case.
  • Page 149 1. Holder (× 5) 2. Air filter case cover 3. Remove the air filter element. 1. Frame 2. Air filter element 1. Air filter element 8-35...
  • Page 150 7. Inspect the air filter element and replace frame. it if damaged. 5. Wash the air filter element gently but 8. Apply Yamaha foam air filter oil or other thoroughly in solvent. quality foam air filter oil to the air filter el- ement.
  • Page 151 11. Install the air filter case cover and be sure CAUTION: to connect the hose. Never operate the engine with the air filter 12. Install the seat. element removed. This will allow unfiltered NOTE: air to enter, causing rapid engine wear and The air filter element should be cleaned every possible engine damage.

  • Page 152: Spark Arrester Cleaning

    EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon depos- its from the spark arrester portion of the tailpipe.

  • Page 153: V-Belt Cooling Duct Check Hose

    EBU06411 V-belt cooling duct check hose WARNING If dust or water collects in the V-belt cooling POTENTIAL HAZARD duct check hose, remove the hose and clean Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes. Could cause burns.

  • Page 154: V-Belt Case Drain Plug

    V-belt case, remove this plug to requires very sophisticated adjustment. Most drain the water from the case. adjusting should be left to a Yamaha dealer who has the professional knowledge and ex- NOTE: perience to do so. However, the idling speed...

  • Page 155: Idle Speed Adjustment

    To prevent this, the valve clear- increase the engine speed, and in direc- ance must be adjusted regularly. This adjust- tion b to decrease the engine speed. ment however, should be left to a professional Yamaha service technician. Specified idle speed: 1,450–1,550 r/min 8-41...

  • Page 156: Throttle Lever Adjustment

    This adjustment, however, should be left 1. Loosen the locknut. to a Yamaha dealer. 2. Turn the adjusting bolt until the throttle le- ver free play is 3–5 mm (0.12–0.20 in).

  • Page 157: Front Brake Pad Check

    Check the brake pads for damage and wear. If a brake pad thickness is less than 1 mm If the thickness is less than 1.0 mm (0.04 in), (0.04 in), have a Yamaha dealer replace the have a Yamaha dealer replace the pads. pads as a set.

  • Page 158: Checking The Brake Fluid Level

    EBU08751 Checking the brake fluid level FRONT Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level and replenish when necessary. A low brake fluid level may indi- cate worn brake pads and/or brake system leakage.
  • Page 159 Always clean up spilled the top of the master cylinder reservoirs are fluid immediately. level. Have a Yamaha dealer check the cause if Use only the designated quality brake fluid, the brake fluid level goes down. otherwise the rubber seals may deteriorate, causing leakage and poor brake perfor- mance.

  • Page 160: Brake Fluid Replacement

    Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. Replace the oil seals every two years.

  • Page 161: Front Brake Lever Free Play

    The front brake lever should have a free play POTENTIAL HAZARD of zero mm (zero in) at the lever end. If not, Operating with improperly serviced or have a Yamaha dealer check the brake sys- adjusted brakes. tem. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.

  • Page 162: Adjusting The Rear Brake Lever And Brake Pedal

    2 mm (0.02–0.08 in). If correct free play cannot be obtained, ask a 1. Loosen the locknut. Yamaha dealer to make that adjustment. NOTE: When adjusting the rear brake lever free play: Be sure not to step on the brake pedal.
  • Page 163 The top of the brake pedal should be posi- POTENTIAL HAZARD tioned 72 mm (2.8 in) above the top of the Operating with improperly serviced or footrest. If not, ask a Yamaha dealer to adjust adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.

  • Page 164: Adjusting The Rear Brake Light Switch

    EBU12590 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and rear brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If neces- sary, adjust the brake light switch as follows. 1.

  • Page 165: Cable Inspection And Lubrication

    Inspect cables frequently. Replace dam- aged cables. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-51...

  • Page 166: Rear Knuckle Upper And Lower Pivot Lubrication

    EBU13110 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun. 1. Upper knuckle 2. Lower knuckle Recommended lubricant: Lithium-soap-based grease 8-52...

  • Page 167: Wheel Removal

    EBU01112 EBU01121 Wheel removal Wheel installation 1. Loosen the wheel nuts. 1. Install the wheel and the nuts. 2. Elevate the ATV and place a suitable NOTE: stand under the frame. Tapered nuts are used for both the front 3. Remove the nuts from the wheel. and rear wheels.
  • Page 168 1. Tapered nut 2. Lower the ATV so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf) 8-54...

  • Page 169: Battery

    Keep out of reach of chil- tery. If the battery seems to have discharged, dren. consult a Yamaha dealer. Antidote: EXTERNAL: Flush with water. CAUTION: INTERNAL: Drink large quantities of wa- Do not try to remove the sealing caps of ter or milk.

  • Page 170: Battery Maintenance

    CAUTION: amperage. Turn on the main switch. If A special battery charger (constant volt- the fuse immediately blows again, con- age/ampere or constant voltage) is re- sult a Yamaha dealer. quired recharging sealed-type battery. Using a conventional battery charger may shorten the battery life.
  • Page 171 WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rat- 1. Main fuse 2.

  • Page 172: Replacing A Headlight Bulb

    EBU11252 Replacing a headlight bulb If a headlight bulb burns out, replace it as fol- lows. 1. Remove the cover at the rear of the headlight by pulling it off. 1. Headlight bulb holder cover 3. Remove the headlight bulb holder by push- ing it in and turning it counterclockwise.
  • Page 173 4. Remove the defective bulb by pulling it CAUTION: out. Do not touch the glass part of the head- WARNING light bulb to keep it free from oil, otherwise POTENTIAL HAZARD the transparency of the glass, the luminos- A headlight bulb is hot when it is on and ity of the bulb, and the bulb life will be ad- immediately after it is turned off.

  • Page 174: Headlight Beam Adjustment

    EBU01089 Headlight beam adjustment CAUTION: It is advisable to have a Yamaha dealer make this adjustment. To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. 1. Do not touch the glass part of the bulb.

  • Page 175: Tail/Brake Light Bulb Replacement

    EBU15050 Tail/brake light bulb replacement 5. Install the bulb holder (together with the 1. Remove panel G. (See pages 8-14–8-15 bulb). for removal and installation procedures.) 6. Install the panel. 2. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 1.

  • Page 176: Troubleshooting

    EBU00412 Troubleshooting WARNING Although Yamaha machines receive a rigid in- POTENTIAL HAZARD spection before shipment from the factory, Checking the fuel system while smok- trouble may occur during operation. Any prob- ing or near an open flame. lem in the fuel, compression, or ignition sys-...

  • Page 177: Troubleshooting Charts

    No fuel. 2. Compression There is compression. Compression normal. Use the electric starter to see if there is compression. Ask a Yamaha dealer to No compression. inspect. 3. Ignition Wipe clean with dry cloth. Ignition system is Spark is good.

  • Page 178: Engine Overheating

    Restart the engine. If the engine overheats again, ask a Level is OK. Yamaha dealer to inspect and/or repair the cooling system. NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible.

  • Page 179: Cleaning And Storage

    EBU00419 CLEANING AND STORAGE CAUTION: ¯ Excessive water pressure may cause wa- A. CLEANING ter seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend bills have resulted from improper high the useful life of many components.
  • Page 180 6. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after wash- 7. Automotive type wax may be applied to ing. all painted and chrome plated surfaces. WHAT CAN HAPPEN Avoid combination cleaner-waxes.

  • Page 181: Storage

    Do not apply oil to fuel) any rubber parts or the seat cover. NOTE: Use of fuel stabilizer and conditioner elimi- nates the need to drain the fuel system. Con- sult a Yamaha dealer if the fuel system needs to be drained instead.
  • Page 182 7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an ex- cessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine.

  • Page 183: Specifications

    EBU00428 SPECIFICATIONS Model YFM660FA Dimensions: Overall length 2,085 mm (82.1 in) Overall width 1,150 mm (45.3 in) Overall height 1,210 mm (47.6 in) Seat height 880 mm (34.6 in) Wheelbase 1,275 mm (50.2 in) Ground clearance 275 mm (10.8 in) Minimum turning radius 3,200 mm (126.0 in) Basic weight:...
  • Page 184 Model YFM660FA Engine oil: 0° 10° 30° 50° 70° 90° 110° 130°F Type YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20° -10° 0° 10° 20° 30° 40° 50°C Recommended engine oil classification API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the en- gine oil also lubricates the clutch), do not mix any...
  • Page 185 Model YFM660FA Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity 0.25 L (0.22 Imp qt, 0.26 US qt) Differential gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity 0.28 L (0.25 Imp qt, 0.30 US qt) Radiator capacity (including all routes): 1.80 L (1.58 Imp qt, 1.90 US qt) Air filter:...
  • Page 186 Model YFM660FA Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive 41/21 × 24/18 × 33/9 (9.544) Secondary reduction ratio Transmission type V-belt automatic Operation Left hand operation Reverse gear 25/17 (1.471) Sub transmission ratio 35/17 (2.058) high 26/21 (1.238) Chassis: Frame type Steel tube frame...
  • Page 187 Model YFM660FA Brake: Front brake type Dual disc brake operation Right hand operation Rear brake type Single disc brake operation Left hand and right foot operation Suspension: Front suspension Double wishbone Rear suspension Double wishbone Shock absorber: Front shock absorber Coil spring / oil damper Rear shock absorber Coil spring / oil damper...
  • Page 188 Model YFM660FA Bulb voltage, wattage × quantity: 12 V, 30 W / 30 W × 2 Headlight 12 V, 5 W / 21 W × 1 Tail/brake light Indicator light: Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light High-range indicator light Low-range indicator light...

  • Page 189: Noise Regulation

    EBU00430 N OISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate 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 190: Maintenance Record

    EBU13653 M AINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

  • Page 191: Atv Limited Warranty

    EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1...
  • Page 192 13-2...

  • Page 193: Yamaha Extended Service (Y.e.s.)

    EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1...
  • Page 194 EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death. 14-2...
  • Page 195 EBU00437...
  • Page 196 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.03-5.0×1 CR...

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