Yamaha GRIZZLY 660 Owner's Manual
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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
YFM66FGW
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-20-05
2C6-28199-12

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  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM66FGW WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-20-05 2C6-28199-12...
  • 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 ..........4-13 EWB00010 WARNING Front brake lever ........4-14 Indicates a potential hazard that could result Brake pedal and rear brake lever .....4-14 in serious injury or death. Drive select lever ........4-15 Recoil starter ..........4-15 Fuel tank cap ..........4-16 Fuel ............4-16 EBU17420 Fuel cock ..........4-18 TABLE OF CONTENTS...
  • Page 7 Measuring the tire pressure ....... 5-8 SLIDING AND SKIDDING ......7-31 Tire wear limit ..........5-9 WHAT TO DO IF........7-32 Chassis fasteners ........5-9 WHAT TO DO..........7-32 Instruments, lights and switches ....5-9 PERIODIC MAINTENANCE AND MINOR OPERATION ..........6-1 REPAIR ............8-1 Starting a cold engine ........
  • Page 8 Checking and lubricating the Noise regulation ........11-3 brake pedal ..........8-46 Maintenance record ........11-4 Checking the wheel bearings ....8-47 YAMAHA MOTOR CORPORATION, Lubricating the drive shaft U.S.A. ATV LIMITED WARRANTY ..11-5 universal joint ......... 8-47 YAMAHA EXTENDED SERVICE Checking the stabilizer bushes ....8-47 (Y.E.S.) ...........11-7...

  • Page 9: Safety Information

    EBU17430 SAFETY INFORMATION EBU17481 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 10 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 11 steady speed when climbing a hill. If you stall or Always be sure there are no obstacles or people roll backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 12 HOW TO AVOID THE HAZARD EWB00021 WARNING If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- POTENTIAL HAZARD oline in your eyes, seek medical help Improper handling of gasoline. immediately. If gasoline spills on your skin, WHAT CAN HAPPEN wash with soap and water.
  • Page 13 WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad- equate ventilation.

  • Page 14: Location Of The Warning And Specification Labels

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

  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 1. Rear shock absorber assembly spring preload adjusting ring 2. Fuel tank cap 2. Spark arrester 3. Fuel cock 3. Storage compartment and tool kit 4. Oil filter cartridge 4.

  • Page 19: Controls And Instruments

    EBU17712 Controls and instruments NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Drive select lever 2. Rear brake lever 3. Handlebar switches 4. Starter (choke) 5. Multifunction meter unit 6. Main switch 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. EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light 1.

  • Page 21: Indicator Lights And Warning Light

    Indicator lights and warning light NOTE: If the indicator light flashes or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. EBU17860 Neutral indicator light “ ” This indicator light comes on when the transmis- sion is in the neutral position.
  • Page 22 EBU17961 EBU17980 On-Command four-wheel-drive/differential High-range indicator light “ ” gear lock indicator “ ”/“ ” This indicator light comes on when the transmis- DIFF. LOCK The On-Command four-wheel-drive indicator “ ” sion is in the high-range position. comes on when the On-Command four-wheel- EBU17990 drive switch is set to the “4WD”...

  • Page 23: Multifunction Display

    two tripmeters (which show the distance trav- EBU18040 Multifunction display eled since they were last set to zero) a clock an hour meter (which shows the total time the key has been turned to “ON”) a fuel meter Odometer and tripmeter modes Pushing the “TRIP/ODO”...
  • Page 24 Clock mode Pushing the “ ”/“ ” button switches the display between the clock mode “CLOCK” and the hour meter mode “HOUR” in the following order: CLOCK → HOUR → CLOCK To set the clock 1. Set the display to the clock mode. 2.

  • Page 25: Handlebar Switches

    EBU18060 EBU18100 Handlebar switches Start switch “ ” 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. EBU18151 Light switch “ /OFF” Set this switch to “ ”...
  • Page 26 Top speed is normally limited when operating in indicate a malfunction in the electrical system. In differential gear lock. If conditions require more en- this case, take the ATV to a Yamaha dealer at the gine power when riding forward, push and hold this first opportunity.
  • Page 27 WHAT CAN HAPPEN To change from two-wheel drive to four-wheel All wheels turn at the same speed when the drive, stop the ATV and push the switch in to the differential is locked, so it takes more effort “4WD” position. Then, the four-wheel-drive indica- to turn the ATV.
  • Page 28 EWB00120 EBU18242 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 29 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 30 WHAT CAN HAPPEN EWB00091 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 31: Throttle Lever

    When the ATV is in four-wheel-drive differential gear lock, the maximum traveling speed is limit- ed to 35 km/h (22 mi/h). However, if conditions require full engine power to be available, push and hold the override switch to disable the differ- ential gear lock speed limiter.

  • Page 32: Speed Limiter

    If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a 1. Locknut Yamaha dealer if you can’t find or solve the 2. Adjusting screw problem yourself. 3. No more than 12 mm (0.47 in) EBU18311 3.

  • Page 33: Front Brake Lever

    WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result. You could lose control, have an accident or be in- jured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in).

  • Page 34: Drive Select Lever

    EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. 1.

  • Page 35: Fuel Tank Cap

    EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Recoil starter EWB00290 WARNING POTENTIAL HAZARD 1. Fuel tank cap Starting the engine without setting the drive select lever to the park position. EBU18730 Fuel WHAT CAN HAPPEN Make sure that there is sufficient fuel in the tank.
  • Page 36 Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher.

  • Page 37: Fuel Cock

    WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere 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. HOW TO AVOID THE HAZARD Do not overfill the fuel tank.

  • Page 38: Starter (Choke)

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

  • Page 39: Seat

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Seat 2. Seat lock lever To install the seat Insert the projections on the front of the seat into 1.

  • Page 40: Storage Compartment

    ECB00130 CAUTION: Do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartment. 1. Projection 2. Seat holder EBU27090 Storage compartment The storage compartment is located under the seat.

  • Page 41: Front Carrier

    The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. NOTE: NOTE: A special wrench can be obtained at a Yamaha The rear wheels need to be removed to adjust the dealer to make this adjustment. rear shock absorber assemblies. (See page 8-54.) Adjust the spring preload as follows.

  • Page 42: Auxiliary Dc Jack

    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 43 Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A) 4. When the auxiliary DC jack is not being used, cover it with the cap. ECB00120 CAUTION: Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to 1.

  • Page 44: Pre-Operation Checks

    Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 45 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check lever free play, and adjust if necessary. Rear brake • Check brake pads for wear, and replace if necessary. 5-5, 8-38, 8-39, 8-41 •...
  • Page 46 EWB00470 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. 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 it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Own- er’s Manual.

  • Page 47: Fuel

    EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. Make sure that the final gear oil is at the specified (See page 4-16.) level. Add oil as necessary. (See page 8-22.) EWB00500 WARNING EBU19600 Differential gear oil POTENTIAL HAZARD...

  • Page 48: Front And Rear Brakes

    Check that there is no free play in the front brake If there is any leakage, the brake system should be lever. If there is free play, have a Yamaha dealer checked by a Yamaha dealer. adjust it.

  • Page 49: Throttle Lever

    Do not ride the ATV if you find any prob- lem with the brakes. If a problem cannot be corrected by the adjustment procedures pro- vided in this manual, have a Yamaha dealer check for the cause. EBU19761 Throttle lever Check the operation of the throttle lever.

  • Page 50: Tires

    HOW TO AVOID THE HAZARD Rear: The tires listed below have been approved 30 kPa (4.3 psi) (0.30 kgf/cm²) by Yamaha Motor Co., Ltd. for this model. • Check and adjust tire pressures when Other tire combinations are not recom- the tires are cold.

  • Page 51: 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 32 kPa (4.6 psi) (0.32 kgf/cm²)

  • Page 52: Tire Wear Limit

    Recommended pressure: Front 35 kPa (5.0 psi) (0.35 kgf/cm²) Rear 30 kPa (4.3 psi) (0.30 kgf/cm²) Minimum: Front 32 kPa (4.6 psi) (0.32 kgf/cm²) Rear 27 kPa (3.9 psi) (0.27 kgf/cm²) Maximum: 1. Tire wear limit Front 38 kPa (5.5 psi) (0.38 kgf/cm²) EBU19840 Chassis fasteners Rear...

  • Page 53: Operation

    Read the Owner’s Manual carefully. If there is prior to operating the engine for the first time. a control or function you do not understand, ask your Yamaha dealer. 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “...
  • Page 54 3. Shift the drive select lever into the neutral or Ambient temp./starter (choke) position park position. The corresponding indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. NOTE: The engine can be started under the following con-...

  • Page 55: 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 56 The drive select lever cannot be shifted into or from should come on. If the indicator light does not reverse or park without applying the brake pedal. come on, have a Yamaha dealer check the elec- trical circuit. 1. Bring the ATV to a complete stop.

  • Page 57: Engine Break-In

    There is never a more important period in the life of If any engine trouble should occur during the your engine than the first 20 hours of riding. For engine break-in period, immediately have a this reason, you should read the following material Yamaha dealer check the ATV. carefully.

  • Page 58: Parking

    Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of gen- 1. Bring the ATV to a stop by applying the uine Yamaha accessories. Other accessories brakes.
  • Page 59 Yamaha to test all non- Never exceed the weight limits shown. An over- Yamaha accessories, nor control over their qual- loaded ATV can be unstable. ity or suitability. Choose a genuine Yamaha ac- MAXIMUM LOADING LIMIT...
  • Page 60 the weight on the hitch. If you are carrying cargo EWB00750 WARNING and towing a trailer, include the tongue weight in the maximum ATV load limit. POTENTIAL HAZARD Load cargo on the carriers as close to the center Overloading this ATV or carrying or towing of the ATV as possible.

  • Page 61: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 62: Getting To Know Your Atv

    ular attention to the safety information on pages EWB00010 WARNING 1-1–1-5. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. RIDE WITH CARE AND GOOD JUDGEMENT EBU21201 Get training if you are inexperienced.
  • Page 63 Yamaha. They should then ry or death of the child. regularly practice the skills learned in the HOW TO AVOID THE HAZARD course and the operating techniques de- A child under 16 should never operate an scribed in this Owner’s Manual.
  • Page 64 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 65 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 66 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 67 Do not operate at speeds too fast for your skills EWB00950 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 68 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 69 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 70 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 71 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 72: 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 73 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 74 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 75 EWB01050 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 ATV control, which could result in an accident, including an overturn. 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...
  • Page 76 When riding in an area where you might not easily HOW TO AVOID THE HAZARD be seen, such as desert terrain, mount a caution Always mount a caution flag on the ATV to flag on the ATV. DO NOT use the flag pole bracket make you more visible.
  • Page 77 surfaces: the ATV is designed for off-road use ECB00250 CAUTION: only, and handling maneuvers are more difficult to perform on pavement. Do not shift from drive position low-range to Shift to the park position and follow the instruction high-range or vice versa without coming to a on page 6-1 to start the engine.

  • Page 78: Turning Your Atv

    TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off-road Always follow proper procedures for turning in 2WD or 4WD, the two rear wheels turn together as described in this Owner’s Manual. Prac- at the same speed. Furthermore, when riding in tice turning at low speeds before attempting 4WD-LOCK (“DIFF.
  • Page 79 Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.

  • Page 80: Climbing Uphill

    CLIMBING UPHILL EWB01180 WARNING Use proper riding techniques to avoid ATV over- turns on hills. Be sure that you can maneuver your POTENTIAL HAZARD ATV well on flat ground before attempting any in- Climbing hills improperly. cline and then practice riding first on gentle slopes. WHAT CAN HAPPEN Try more difficult climbs only after you have devel- Could cause loss of control or cause the...
  • Page 81 7-21...
  • Page 82 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 83 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 84: 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 85 7-25...

  • Page 86: 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 87 7-27...

  • Page 88: 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 89 1. Air filter case check hose ECB00270 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 and the drive select lever box check hose.

  • Page 90: Riding Over Rough Terrain

    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. Be sure to keep your feet firmly mounted on the footboards at all times.

  • Page 91: 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 92: What To Do If

    With practice, over a period of time, skill at con- WHAT TO DO IF... trolled sliding can be developed. The terrain This section is designed to be a reference guide should be chosen carefully before attempting such only. Be sure to read each section on riding tech- maneuvers, since both stability and control are re- niques completely.
  • Page 93 THE REAR BRAKE IF THE ATV IS IN 2WD – the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See page 7-20.) If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance.

  • Page 94: 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 95 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 96: 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 97 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 98: General Maintenance And Lubrication Chart

    EBU21862 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 99 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Upper and lower √ √ √ • Lubricate with lithium-soap-based grease. arm pivots • Check for wear, cracks or other damage, and re- √...
  • Page 100 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Change. √ √ Differential gear oil • Check ATV for oil leakage, and correct if neces- sary. •...
  • Page 101 EBU23070 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 102: Removing And Installing Panels

    EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed.
  • Page 103 To install one of the panels 1. Insert the panel projections in the numerical order shown in the illustration, and then push inward on the area shown. 1. Panel A 1. Panel A 1. Panel D 8-10...
  • Page 104 1. Panel D 1. Panel B 2. Bolt 2. Install the seat. To install the panel Panel B Place the panel in the original position and install To remove the panel the bolts. Remove the bolts, and then take the panel off. ECB00380 CAUTION: When installing the panel, be sure not to pinch...
  • Page 105 1. Front carrier stay cover 1. Carrier bolt (top) 1. Carrier bolt (top) 1. Carrier bolt (under the fenders) 2. Remove the quick fasteners and pull the pan- el upward. 8-12...
  • Page 106 Panel E To remove the panel Remove the bolts, and then take the panel off. 1. Quick fastener 2. Panel C To install the panel 1. Panel E 1. Place the panel in the original position and in- 2. Bolt stall the quick fasteners.
  • Page 107 Panel G To remove the panel 1. Remove the seat. (See page 4-20.) 2. Remove the rear carrier by removing the bolts. 1. Panel F To install the panel Place the panel in its original position. 1. Carrier bolt (top) 8-14...
  • Page 108 1. Carrier bolt (under the fenders) 1. Seat under bracket 2. Panel G 3. Remove the seat under bracket and the panel by pulling them off. To install the panel 1. Place the panel and the seat under bracket in the original position.

  • Page 109: Checking The Spark Plug

    NOTE: If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not 1. Spark plug cap attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-16...
  • Page 110 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DPR8EA-9 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 111: Engine Oil And Oil Filter Cartridge

    NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4.
  • Page 112 To change the engine oil (with or without oil fil- ter cartridge replacement) 1. Remove panel F. (See page 8-9.) 2. Place the ATV on a level surface. 3. Start the engine, warm it up for several min- utes, and then turn it off. 4.
  • Page 113 1. Oil filter cartridge 2. Oil filter wrench NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
  • Page 114 12. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 1.90 L (2.01 US qt) (1.67 Imp.qt) With oil filter cartridge replacement: 2.00 L (2.11 US qt) (1.76 Imp.qt) 1.

  • Page 115: Changing The Final Gear Oil

    If any leakage is found, have 1. Final gear oil filler bolt a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil must be changed as follows at the intervals specified in the periodic mainte- nance and lubrication chart.

  • Page 116: Differential Gear Oil

    23 Nm (2.3 m·kgf, 17 ft·lbf) leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. 5. Add the specified amount of the recommend- In addition, the differential gear oil level must be ed final gear oil.

  • Page 117: To Change Differential Gear Oil

    To change the differential gear oil 1. Place the ATV on a level surface. 2. Place an oil pan under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case.

  • Page 118: Coolant

    5. Add the recommended differential gear oil to Tightening torque: the brim of the filler hole as shown. 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. EBU23470 Coolant The coolant level should be checked before each...
  • Page 119 1. Coolant reservoir cap If water has been added to the coolant, have 2. Maximum level mark a Yamaha dealer check the antifreeze con- 3. Minimum level mark tent of the coolant as soon as possible, oth- 3. If the coolant is at or below the minimum level erwise the effectiveness of the coolant will mark, remove panel D.
  • Page 120 If the engine overheats, see page 8-57 for fur- ther instructions. EBU23591 To change the coolant EWB01880 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam 1.
  • Page 121 5. Remove the radiator cap. 1. Coolant reservoir hose 1. Radiator cap 9. After draining the coolant, thoroughly flush the 6. Remove panel D. (See page 8-9.) cooling system with clean tap water. 7. Remove the coolant reservoir cap. 10. Replace the coolant drain bolt washer if it is 8.

  • Page 122: Cleaning The Air Filter Element

    Coolant reservoir capacity (up to the maxi- leakage. mum level mark): 0.30 L (0.32 US qt) (0.26 Imp.qt) NOTE: If any leakage is found, have a Yamaha dealer ECB00400 check the cooling system. CAUTION: 17. Install the panels and the front carrier.
  • Page 123 NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air fil- ter case. 1. Air filter case holder 2.
  • Page 124 1. Air filter element 1. Air filter element frame 2. Sponge material 4. Remove the sponge material from the air filter element frame. 5. Wash the sponge material gently but thor- oughly in solvent. EWB01900 WARNING POTENTIAL HAZARD Using low-flash-point solvents or gasoline to clean the sponge material.
  • Page 125 Do not twist the sponge material when squeez- ing it. 7. Check the sponge material and replace it if damaged. 8. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. NOTE: 1. Breather hose The sponge material should be wet but not drip- 11.

  • Page 126: Cleaning The Spark Arrester

    ECB00460 CAUTION: Make sure that the air filter element is prop- erly seated in the air filter case. Never operate the engine with the air filter el- ement removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage.

  • Page 127: V-Belt Cooling Duct Check Hose

    WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components.

  • Page 128: 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 129: Adjusting The Engine Idling Speed

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

  • Page 130: Adjusting The Throttle Cable Free Play

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

  • Page 131: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm EBU24221 Rear brake pads (0.04 in), have a Yamaha dealer replace the brake Check each rear brake pad for damage and mea- pads as a set. sure the lining thickness. If a brake pad is dam- aged or if the lining thickness is less than 1.5 mm...

  • Page 132: Checking The Brake Fluid Level

    Front brake 1. Brake pad 1. Minimum level mark 2. Lining thickness Rear brake EBU24261 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary.

  • Page 133: Changing The Brake Fluid

    When checking the fluid level, make sure that Changing the brake fluid the top of the brake fluid reservoir is level. Have a Yamaha dealer change the brake fluid at Use only the recommended quality brake fluid, the intervals specified in the NOTE after the peri- otherwise the rubber seals may deteriorate, odic maintenance and lubrication chart.

  • Page 134: Adjusting The Rear Brake Lever Free Play And Checking The Brake Pedal Position

    Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU27130 1. Brake lever free play Adjusting the rear brake lever free play...
  • Page 135 2. Brake lever free play adjusting bolt 3. Tighten the locknut. If the correct free play cannot be obtained, have a 1. Brake lever free play Yamaha dealer adjust it. 1. Loosen the locknut. NOTE: 2. Turn the brake lever free play adjusting bolt in...

  • Page 136: Axle Boots

    Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 137: Brake Light Switches

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

  • Page 138: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Lithium-soap-based grease (all-purpose grease)

  • Page 139: Checking And Lubricating The Brake Pedal

    Front brake lever EBU24950 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. NOTE: To access the brake pedal pivot, remove panel B. (See page 8-9.) Recommended lubricant: Lithium-soap-based grease (all-purpose...

  • Page 140: Checking The Wheel Bearings

    If there is play at the intervals specified in the periodic mainte- in a wheel hub or if a wheel does not turn smoothly, nance and lubrication chart. have a Yamaha dealer check the wheel bearings. Recommended lubricant: EBU24980 Lithium-soap-based grease...

  • Page 141: Battery

    EWB02140 WARNING POTENTIAL HAZARD Failure to handle batteries or battery electro- lyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be se- verely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gas- HOW TO AVOID THE HAZARD 1.
  • Page 142 To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.

  • Page 143: Replacing A Fuse

    EBU25312 ECB00640 Replacing a fuse CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A...

  • Page 144: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25470 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 145 3. Remove the headlight bulb holder by pushing 5. Insert a new headlight bulb into the bulb hold- it in and turning it counterclockwise. er by pushing it in. 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. 4.

  • Page 146: Adjusting A Headlight Beam

    ECB00690 1. Headlight beam adjusting screw CAUTION: EBU25640 It is advisable to have a Yamaha dealer make Replacing the tail/brake light bulb this adjustment. If the tail/brake light bulb burns out, replace it as To raise a headlight beam, turn the adjusting follows.

  • Page 147: Removing A Wheel

    1. Tail/brake light bulb holder 1. Wheel nut 3. Remove the defective bulb by pushing it in 2. Elevate the ATV and place a suitable stand and turning it counterclockwise. under the frame. 4. Insert a new bulb into the bulb holder, push it 3.
  • Page 148 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 1.

  • Page 149: 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 150: Troubleshooting Charts

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.
  • Page 151 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.

  • Page 152: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE ed from improper high-pressure detergent EBU25870 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 153: Storage

    To prevent corrosion, avoid damp cellars, EWB02300 WARNING stables (because of the presence of ammo- nia) and areas where strong chemicals are POTENTIAL HAZARD stored. Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping abil- Long-term ity, increasing the chance of an accident.
  • Page 154 b. Pour a teaspoonful of engine oil into the sively cold or warm place [less than 0 °C (30 spark plug bore. °F) or more than 30 °C (90 °F)]. For more in- c. Install the spark plug cap onto the spark formation on storing the battery, see page plug, and then place the spark plug on the 8-48.

  • Page 155: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.10 :1 Overall length: Starting system: 2085 mm (82.1 in) Electric and recoil starter Overall width: Lubrication system: 1150 mm (45.3 in) Wet sump Overall height: Engine oil: 1210 mm (47.6 in) Seat height: Type: 880 mm (34.6 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase:...
  • Page 156 With oil filter cartridge replacement: Type x quantity: 2.00 L (2.11 US qt) (1.76 Imp.qt) BSR42 x 1 Final gear oil: Spark plug (s): Type: Manufacturer/model: SAE80 API GL-4 Hypoid gear oil NGK/DPR8EA-9 Quantity: Spark plug gap: 0.25 L (0.26 US qt) (0.22 Imp.qt) 0.8–0.9 mm (0.031–0.035 in) Differential gear oil: Clutch:...
  • Page 157 Caster angle: Rear: 5.0 ° 27 kPa (3.9 psi) (0.27 kgf/cm²) Trail: Maximum: 26.0 mm (1.02 in) Front: Front tire: 38 kPa (5.5 psi) (0.38 kgf/cm²) Rear: Type: 33 kPa (4.8 psi) (0.33 kgf/cm²) Tubeless Front wheel: Size: AT25 x 8-12 Wheel type: Manufacturer/model: Panel wheel...
  • Page 158 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Neutral indicator light: Double wishbone Spring/shock absorber type: Reverse indicator light: Coil spring/oil damper Wheel travel: Coolant temperature warning light: 170.0 mm (6.69 in) Rear suspension: Park indicator light: Type: Double wishbone On-Command four-wheel-drive/differential gear lock...
  • Page 159 Four-wheel-drive motor fuse: 3.0 A 10-5...

  • Page 160: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 161 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 162: 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 163: 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 164: 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 165 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 166: 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 167 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 168 EBU26132 11-9...
  • Page 169 INDEX Accessories and loading ..........6-6 Differential gear lock indicator light ........ 4-3 Accessories, auxiliary jack ........... 4-23 Differential gear oil ..........5-4, 8-23 Air filter element, cleaning ..........8-29 Drive select lever ............4-15 Axle boots ..............8-43 Drive select lever and driving in reverse ......6-3 Drive select lever safety system cable, adjusting ..
  • Page 170 Pre-operation check list ..........5-1 Identification numbers ..........11-1 Indicator lights and warning light ........4-2 Recoil starter ..............4-15 Instruments, lights and switches ........5-9 Reverse indicator light ............ 4-2 Riding your ATV ............. 7-1 Key identification number ..........11-1 Knuckle pivots, lubricating ..........
  • Page 171 V-belt case drain plug ..........8-35 V-belt cooling duct check hose ........8-34 Vehicle identification number ........11-1 Warranty, extended ............11-7 Warranty, limited ............11-5 Wheel bearings, checking ..........8-47 Wheel, installing ............8-54 Wheel, removing ............8-54...
  • Page 172 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 2006.03-3.0×1 CR...

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