Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM7FGX WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-21-01 5C0-28199-10...
Page 2 EBU17091...
Page 3 INTRODUCTION EBU17270 Congratulations on your purchase of the Yamaha YFM7FGX. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
Page 4 EBU17330 IMPORTANT MANUAL INFORMATION 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 ..........4-14 EWB00010 WARNING Front brake lever ........4-15 Brake pedal and rear brake lever .....4-15 Indicates a potential hazard that could result in serious injury or death. Drive select lever ........4-16 Fuel tank cap ..........4-16 Fuel ............4-17 Seat ............4-19 EBU17420 Storage compartments ......4-19 TABLE OF CONTENTS...
Page 7 Instruments, lights and switches ....5-9 PERIODIC MAINTENANCE AND MINOR REPAIR ..........8-1 OPERATION ..........6-1 Owner’s manual and tool kit .......8-1 Starting the engine ........6-1 Periodic maintenance chart Operating the drive select lever and for the emission control system ....8-3 driving in reverse ........
Page 8 Checking and lubricating the cables ..8-52 Noise regulation ........11-3 Checking and lubricating the front and Maintenance record ........11-4 rear brake levers ........8-53 YAMAHA MOTOR CORPORATION, Checking and U.S.A. ATV LIMITED WARRANTY ..11-5 lubricating the brake pedal ..... 8-53 YAMAHA EXTENDED SERVICE Checking the wheel hub bearings ....
Page 9: Safety Information
EBU17430 SAFETY INFORMATION EBU27230 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 EWB02320 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- POTENTIAL HAZARD oline in your eyes, seek medical help Improper handling of gasoline. immediately. If gasoline spills on your skin, WHAT CAN HAPPEN wash with soap and water.
Page 13: Location Of The Warning And Specification Labels
EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
Page 14 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 17: Description
EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 1. Rear shock absorber assembly spring preload adjusting ring 2. Battery 2. Rear storage compartment and tool kit 3. Fuses 3. Fuel tank cap cover 4. Air filter case 4.
Page 18: Controls And Instruments
EBU17712 NOTE: Controls and instruments 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. Rear brake fluid reservoir 5. Multifunction display 6. Front brake fluid reservoir 7.
Page 19: 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 20: Indicator Lights And Warning Lights
The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on, have a Yamaha dealer 1. On-Command differential gear lock indicator light “DIFF. check the electrical circuit.
Page 21 ATV starts moving. When this occurs, have a Yamaha dealer check When the On-Command differential gear lock the self-diagnosis system. (See page 4-4 for an ex- switch is set to “LOCK”, the indicator “...
Page 22: Multifunction Display
EBU18001 EBU27291 On-Command differential gear lock indicator Multifunction display light “DIFF. LOCK” This indicator light and the On-Command differen- tial gear lock indicator in the display come on when the On-Command differential gear lock switch is set to the “LOCK” position. NOTE: When the switch is set to “LOCK”, the On-Com- mand differential gear lock indicator light will flash...
Page 23 CLOCK → HOUR → CLOCK a clock an hour meter (which shows the total time the To set the clock key has been turned to “ON”) 1. Set the display to the clock mode. a fuel meter 2. Push the “SELECT” button and “RESET” but- a self-diagnosis device ton together for at least three seconds.
Page 24 This fuel meter is equipped with a self-diagnosis system. If the electrical circuit is defective, all the display segments and fuel level warning indicator will start flashing. If this occurs, have a Yamaha dealer check the electrical circuit. 1. Error code display This model is equipped with a self-diagnosis de- vice for various electrical circuits.
Page 25: Handlebar Switches
EBU18061 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 EBU18243 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 EWB00091 WHAT CAN HAPPEN WARNING All wheels turn at the same speed when the differential gear is locked, so it takes more POTENTIAL HAZARD effort to turn the ATV. The effort needed to Changing from four-wheel drive to four- turn increases with the riding speed. You wheel-drive differential gear lock or vice-ver- may lose control and have an accident if you sa while the ATV is moving.
Page 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
To install the fuel tank cap Install the fuel tank cap by turning it clockwise until a click is heard, and then close the fuel tank cap cover. EBU18730 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
Page 36 HOW TO AVOID THE HAZARD Your Yamaha engine has been designed to use Do not overfill the fuel tank. Be careful not to regular unleaded gasoline with a pump octane...
Page 37: Seat
EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear. 1. Projection 2. Seat holder EBU27361 Storage compartments This ATV is equipped with two storage compart- ments. 1. Seat The front storage compartment is located at the 2.
Page 38 The rear storage compartment is located under the seat. (See page 4-19.) To access the storage com- partment, remove the storage compartment cover. 1. Front storage compartment cover 1. Rear storage compartment cover 1. Front storage compartment 4-20...
Page 39 Do not exceed the load limit of 0.5 kg (1 lb) for the front storage compartment or 2.0 kg (4 lb) for the rear storage compartment. Do not exceed the maximum load of 220.0 kg (485 lb) for the ATV. NOTE: A drain plug is fitted at the bottom of each storage compartment.
Page 40: Front Carrier
EBU19130 Adjusting the front and rear shock ab- sorber assemblies The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspen- sion, and in direction (b) to decrease the spring preload and thereby soften the suspension.
Page 41: Auxiliary Dc Jack
EWB00350 NOTE: WARNING A special wrench can be obtained at a Yamaha POTENTIAL HAZARD dealer to make this adjustment. Improper shock absorber assembly adjust- ment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident.
Page 42 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 43: Pre-Operation Checks
Manual. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer. ITEM...
Page 44 5-4, 8-31 • Check cooling system for leakage. Correct if necessary. • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-5, 8-45, 8-47, 8-48 •...
Page 45 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate lever pivoting points if Brake levers 8-53 necessary. Axle boots • Check for cracks or damage, and replace if necessary. 8-51 Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. Instruments, lights and •...
Page 46: 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 4-17.) level. Add oil as necessary. (See page 8-26.) EWB00500 WARNING EBU19600 Differential gear oil POTENTIAL HAZARD...
Page 47: Front And Rear Brakes
Yamaha dealer adjust Check the operation of the brake levers and pedal. They should move smoothly and there should be a firm feeling when the brakes are ap- plied. If not, have a Yamaha dealer check the brake system.
Page 48: Throttle Lever
HOW TO AVOID THE HAZARD vided in this manual, have a Yamaha dealer The tires listed below have been approved check for the cause. by Yamaha Motor Co., Ltd. for this model.
Page 49: Measuring The Tire Pressure
Rear: Tire pressure below the minimum speci- Manufacturer/model: fied could cause the tire to dislodge from DUNLOP/KT425 the rim under severe riding conditions. Size: Minimum tire pressure: AT25 x 10-12 Front: Type: 32.0 kPa (4.6 psi) (0.320 kgf/cm²) Tubeless Rear: The tires should be set to the recommend- 27.0 kPa (3.9 psi) (0.270 kgf/cm²) ed pressure:...
Page 50: Tire Wear Limit
Recommended pressure: NOTE: Front The low-pressure tire gauge is included as stan- 35.0 kPa (5.0 psi) (0.350 kgf/cm²) dard equipment. Make two measurements of the Rear tire pressure and use the second reading. Dust or 30.0 kPa (4.3 psi) (0.300 kgf/cm²) dirt in the gauge could cause the first reading to be Minimum: incorrect.
Page 51: Chassis Fasteners
1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.
Page 52: 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 main switch to “ON” and the engine stop switch to “...
Page 53 5. Continue warming up the engine until it idles The corresponding indicator light should smoothly. come on. If the indicator light does not come ECB00160 on, have a Yamaha dealer check the electrical CAUTION: circuit. For maximum engine life, always warm the en- NOTE: gine up before starting off.
Page 54: Operating The Drive Select Lever And Driving In Reverse
EBU20430 Operating the drive select lever and driving in reverse ECB00170 CAUTION: Before shifting, stop the ATV, otherwise the transmission may be damaged. Shifting: Neutral to High-range and High-range to Low-range 1. Bring the ATV to a complete stop. 1. Drive select lever 2.
Page 55: Engine Break-In
For ATVs equipped with an odometer or an hour should come on. If the indicator light does not meter, follow the figures given in km (mi) or the come on, have a Yamaha dealer check the elec- figures given in hours. trical circuit.
Page 56: Parking
There is never a more important period in the life of engine break-in period, immediately have a your engine than the first 320 km (200 mi) or 20 Yamaha dealer check the ATV. hours of riding. For this reason, you should read the following material carefully.
Page 57: Accessories And Loading
However, 2. Stop the engine. it is not possible for Yamaha to test all non- 3. With the brake pedal applied, shift the drive Yamaha accessories, nor control over their qual- select lever to the park position.
Page 58 could make steering difficult, an accessory that MAXIMUM LOADING LIMIT limits your ability to move around on the seat, or ATV loading limit (total weight of rider, cargo, one that limits your view. accessories, and tongue): Use extra caution when riding an ATV with ac- 220.0 kg (485 lb) cessories.
Page 59 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 60: Riding Your Atv
EBU21131 RIDING YOUR ATV...
Page 61: Getting To Know Your Atv
EWB00010 ular attention to the safety information on pages WARNING 1-1–1-4. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. EBU27391 GETTING TO KNOW YOUR ATV This ATV is mainly for utility use, but may also be used for recreation.
Page 62: Ride With Care And Good Judgement
Beginners should get training from a certified in- course offered by Yamaha. They should then structor. regularly practice the skills learned in the Become familiar with this ATV at slow speeds first, course and the operating techniques de- even if you are an experienced operator.
Page 63 WHAT CAN HAPPEN Use by children of ATVs that are not recom- mended for their age can lead to severe inju- ry or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.
Page 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 EWB00950 Do not operate at speeds too fast for your skills WARNING or the conditions. EWB00960 POTENTIAL HAZARD WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Operating this ATV at speeds too fast for Use of improper tires on this ATV, or opera- your skills or the conditions.
Page 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 HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. 7-16...
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 7-22...
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 7-26...
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 7-28...
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 ECB00840 CAUTION: After riding your ATV in water, be sure to drain the trapped water by removing the check hos- es at the bottom of the air filter case. Also, re- move the drain plugs from the front and rear storage compartments and the V-belt case to drain any water that may have accumulated.
Page 90: Riding Over Rough Terrain
1. V-belt case drain plug 1. Storage compartment drain plug RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident.
Page 91: Sliding And Skidding
WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.
Page 92: What To Do If
If the rear wheels of your ATV start to slide side- EWB01170 WARNING ways, control can usually be regained (if there is room to do so) by steering in the direction of the POTENTIAL HAZARD slide. Applying the brakes or accelerating is not Skidding or sliding improperly.
Page 93: What To Do
WHAT TO DO... If your ATV is traversing a sloping surface: If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.
Page 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: General Maintenance And Lubrication Chart
EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
Page 98 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for looseness or damage, and replace if √ √ √ √ Wheel hub bearings necessary. • Check for wear, cracks or other damage, and re- √...
Page 99 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 100 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 101: 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 102 1. Panel E 1. Panel A 2. Panel H To install the panel 3. Panel I Place the panel in the original position. EBU27382 Panel A To remove the panel Pull upward on the areas shown.
Page 103 Panel B To remove the panel 1. Remove panel A. 2. Remove the front carrier by removing the bolts. 1. Carrier bolt (top) 3. Remove the front carrier stays by removing the bolts. 1. Carrier bolt (under the fenders) 1. Front carrier stay 8-10...
Page 104 1. Front carrier stay bolt 1. Panel B 2. Quick fastener 4. Remove the quick fasteners, and then pull the panel upward to remove it. To install the panel 1. Place the panel in the original position, and then install the quick fasteners. 8-11...
Page 105 Tightening torques: Carrier bolt (top): 26 Nm (2.6 m·kgf, 19 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 4. Install panel A. Panel C To remove the panel 1. Remove the seat. (See page 4-19.) 2. Install the front carrier stays by installing the 2.
Page 106 1. Panel C 2. Install panel A. 2. Quick fastener screw 3. Install the seat. To install the panel Panels D and E 1. Place the panel in the original position, and then install the quick fastener screws. To remove one of the panels 1.
Page 107 1. Panel D 1. Panel E 2. Quick fastener screw 2. Quick fastener screw 1. Bolt 1. Bolt 8-14...
Page 108 To install one of the panels Panel F 1. Place the panel in the original position, and To remove the panel then install the bolt and quick fastener screw. Pull outward on the areas shown. 1. Panel F To install the panel Place the panel in the original position.
Page 109 1. Panel G Panels G and H 2. Nut 3. Bolt To remove one of the panels 4. Projection Remove the nut and bolts, and then pull the panel downward while pushing the projection. 8-16...
Page 110 1. Panel H 2. Nut 3. Bolt 4. Projection To install one of the panels Place the panel in the original position, and then in- stall the bolts and nut. Panel I To remove the panel 1. Remove the seat. (See page 4-19.) 8-17...
Page 111 2. Remove the rear carrier by removing the bolts. 1. Carrier bolt (lower) 3. Remove the quick fasteners, and then push 1. Carrier bolt (under the fenders) inward on the areas shown. 1. Carrier bolt (upper) 8-18...
Page 112 1. Panel I 2. Install the rear carrier by installing the bolts 2. Quick fastener and tightening them to the specified torques. To install the panel Tightening torques: 1. Place the panel in the original position, and Carrier bolt (upper): then install the quick fasteners.
Page 113: Removing The Radiator Grills
EBU28671 EBU23211 Removing the radiator grills Checking the spark plug The radiator grills can be removed to access the The spark plug is an important engine component, radiator for cleaning. which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark To remove a radiator grill plug should be removed and checked in accor- Remove the quick fastener, pull the radiator grill...
Page 114: To Check The Spark Plug
(the ideal color when the ATV is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-21...
Page 115: 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 116 4. Remove the dipstick, and then wipe it off with a clean rag. 1. Maximum level mark 2. Minimum level mark 1. Dipstick NOTE: 5. Insert the dipstick completely into the oil filler The engine oil should be between the minimum hole, and then remove it again to check the oil and maximum level marks.
Page 117 1. Oil filter cartridge 2. Oil filter wrench NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 7. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 1. Engine oil drain bolt...
Page 118 1. O-ring 1. Torque wrench Tightening torque: NOTE: Oil filter cartridge: Make sure that the O-ring is properly seated. 17 Nm (1.7 m·kgf, 12 ft·lbf) 8. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to the specified 9.
Page 119: Final Gear Oil
Be sure to wipe off spilled oil on any parts after the age before each ride. If any leakage is found, have engine and exhaust system have cooled down. a Yamaha dealer check and repair the ATV. In ad- ECB00300 dition, the final gear oil level must be checked and...
Page 120 2. Remove the final gear oil level check bolt, and then check the oil level in the final gear case. NOTE: The oil level should be at the brim of the check hole. 1. Final gear oil filler bolt 4. Install the oil level check bolt and oil filler bolt, and then tighten them to the specified torques.
Page 121 3. Remove the final gear oil filler bolt, final gear oil level check bolt, and the final gear oil drain bolt to drain the oil from the final gear case. 1. Final gear oil 2. Final gear oil level check bolt 3.
Page 122: Differential Gear Oil
The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil level must be 1. Differential gear oil checked and the oil changed as follows at the in- 2.
Page 123: Changing Differential Gear Oil
Tightening torque: Tightening torque: Differential gear oil filler bolt: Differential gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 5. Add the recommended differential gear oil to To change the differential gear oil the brim of the filler hole as shown.
Page 124: Coolant
ECB00410 NOTE: CAUTION: The coolant level must be checked on a cold en- Be sure no foreign material enters the differen- gine since the level varies with engine tempera- tial gear case. ture. 6. Install the oil filler bolt, and then tighten it to the 2.
Page 125 If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- erwise the effectiveness of the coolant will 1.
Page 126: Changing Coolant
EBU27553 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 blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing 1.
Page 127 1. Radiator cap 1. Coolant reservoir hose 6. Remove the coolant reservoir cap. 8. After draining the coolant, thoroughly flush the 7. Disconnect the hose on the coolant reservoir cooling system with clean tap water. side, and then drain the coolant from the cool- 9.
Page 128 12. Pour the recommended coolant into the reser- If water has been added to the coolant, have voir to the maximum level mark, and then in- a Yamaha dealer check the antifreeze con- stall the reservoir cap. tent of the coolant as soon as possible, oth-...
Page 129 Tightening torque: Water pump air bleed bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 15. Remove panel E. (See page 8-8.) 16. Loosen the clamp screw, and then remove the V-belt cooling duct. 1. Cylinder head air bleed bolt 18. When coolant begins to flow out of the bolt hole, tighten the cylinder head air bleed bolt to the specified torque.
Page 130: Cleaning The Air Filter Element
23. Start the engine, and then check for coolant leakage. NOTE: If any leakage is found, have a Yamaha dealer check the cooling system. 24. Install the V-belt cooling duct, and then tighten the clamp screw. 25. Install the panels.
Page 131 1. Air filter case check hose 1. Air filter case holder 2. Air filter case cover 1. Remove panel C. (See page 8-9.) 3. Remove the sponge material and the mesh 2. Remove the air filter case cover by unhooking from the air filter case.
Page 132 7. Check the sponge material and replace it if clean the sponge material. damaged. WHAT CAN HAPPEN 8. Apply Yamaha foam air filter oil or other qual- Low-flash-point solvents or gasoline can ity foam air filter oil to the sponge material. catch fire or explode.
Page 133: Cleaning The Spark Arrester
eas. Each time the air filter element maintenance NOTE: is performed, check the air inlet of the air filter case The sponge material should be wet but not drip- for obstructions. Check the air filter case rubber ping. joint to the throttle body and the rubber joint mani- 9.
Page 134 1. Bolt 1. Tailpipe 2. Spark arrester 2. Remove the tailpipe, by pulling it out of the 3. Gasket muffler, and then remove the gasket. 4. Install the gasket, and then insert the tailpipe 3. Tap the tailpipe lightly, and then use a wire into the muffler and align the bolt holes.
Page 135: V-Belt Case Drain Plug
EWB01930 WARNING POTENTIAL HAZARD Improperly purging the exhaust system. Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. 1. Purging bolt HOW TO AVOID THE HAZARD When purging the exhaust system: 7.
Page 136: Adjusting The Engine Idling Speed
NOTE: If water drains from the V-belt case after removing A diagnostic tachometer is needed to make this the plug, have a Yamaha dealer check the ATV as adjustment. the water may affect other engine parts. 1. Start the engine and warm it up.
Page 137: Adjusting The Throttle Cable Free Play
(a). To decrease If the specified idling speed cannot be obtained as the throttle cable free play, turn the adjusting described above, have a Yamaha dealer make the bolt in direction (b). adjustment. 5. Install the panel.
Page 138: Valve Clearance
To prevent this from occurring, the valve clearance NOTE: must be adjusted by a Yamaha dealer at the inter- The wheels need to be removed to check the vals specified in the periodic maintenance and lu- brake pads.
Page 139: Checking The Rear Brake Hose Protectors
Each brake hose protector is provided with a wear indicator. If a protector wears to the point that its indicator be- comes visible, have a Yamaha dealer replace the protector. NOTE: The wheels need to be removed to check the 1.
Page 140: Checking The Brake Fluid Level
Front brake 1. Rear brake hose protector 1. Minimum level mark 2. Wear indicator 3. Protector is normal. Rear brake 4. Protector is worn. EBU24251 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective.
Page 141: Changing The Brake Fluid
Brake fluid may deteriorate painted surfaces or ver should have a free play of zero mm (zero in) as plastic parts. Always clean up spilled fluid imme- shown. If the free play is incorrect, have a Yamaha diately. dealer check the brake system.
Page 142: Adjusting The Brake Pedal 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. EBU27520 Adjusting the brake pedal free play and checking the brake pedal position...
Page 143 2. Brake pedal free play adjusting nut 4. Tighten the locknut. 5. Install the panel. If the correct free play cannot be obtained, have a Yamaha dealer adjust it. NOTE: When adjusting the rear brake pedal free play: 1. Brake pedal free play Be sure not to step on the brake pedal.
Page 144: 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 145: Checking And Lubricating The Cables
If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil 1.
Page 146: Checking And Lubricating The Front And Rear Brake Levers
EBU24912 Rear brake lever Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Recommended lubricant: Silicone grease Front brake lever EBU24951 Checking and lubricating the brake...
Page 147: Checking The Wheel Hub Bearings
If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- ings. EBU25021 Checking the stabilizer bushes...
Page 148: Lubricating The Steering Shaft
EWB02140 To charge the battery WARNING Have a Yamaha dealer charge the battery as soon POTENTIAL HAZARD as possible if it seems to have discharged. Keep in Failure to handle batteries or battery electro- mind that the battery tends to discharge more lyte carefully.
Page 149 To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat- tery. 8-56...
Page 150: Replacing A Fuse
EBU28760 Replacing a fuse 1. Ignition fuse 2. Headlight fuse 1. Fuse box 3. Four-wheel-drive motor fuse 2. Spare main fuse 4. Radiator fan fuse 3. Main fuse 5. Signaling system fuse 4. Fuel injection system spare fuse 6. Auxiliary DC jack fuse 5.
Page 151: Replacing A Headlight Bulb
15.0 A circuits to check if the devices operate. Ignition fuse: 4. If the fuse immediately blows again, have a 10.0 A Yamaha dealer check the electrical system. Four-wheel-drive motor fuse: 10.0 A EBU27430 Replacing a headlight bulb Signaling system fuse: 5.0 A...
Page 152 1. Cover at the rear of the headlight 1. Headlight coupler 2. Remove the headlight bulb cover. 4. Unhook the headlight bulb holder, and then remove the defective bulb. 1. Headlight bulb cover 3. Disconnect the headlight coupler. 8-59...
Page 153 5. Place a new headlight bulb into position, and then secure it with the bulb holder. 1. Headlight bulb holder 2. Headlight bulb 1. Do not touch the glass part of the bulb. EWB02180 WARNING ECB00650 CAUTION: POTENTIAL HAZARD Do not touch the glass part of the headlight A headlight bulb is hot when it is on and im- bulb to keep it free from oil, otherwise the mediately after it is turned off.
Page 154: Adjusting A Headlight Beam
9. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make 1. Headlight beam adjusting screw this adjustment. EBU25640 Replacing the tail/brake light bulb To raise a headlight beam, turn the adjusting screw in direction (a).
Page 155: Removing A Wheel
4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the panel. EBU25650 Removing a wheel 1.
Page 156: Installing A Wheel
EBU25700 Installing a wheel 1. Install the wheel and the nuts. NOTE: The arrow mark on the tire must point toward the rotating direction of the wheel. Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel.
Page 157: 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 158: Troubleshooting Charts
EBU27680 Troubleshooting charts Starting problems or poor engine performance 1. Fuel 2. Compression 3. Ignition 4. Battery 8-65...
Page 159 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 160: Cleaning And Storage
EBU25860 CLEANING AND STORAGE EBU25870 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.
Page 161: Storage
EWB02300 To prevent corrosion, avoid damp cellars, 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 162 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-55.
Page 163: Specifications
EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 2065 mm (81.3 in) Electric starter Overall width: Lubrication system: 1180 mm (46.5 in) Wet sump Overall height: Engine oil: 1240 mm (48.8 in) Seat height: Type: 905 mm (35.6 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase: 1250 mm (49.2 in)
Page 164 With oil filter cartridge replacement: Manufacturer: 2.10 L (2.22 US qt) (1.85 Imp.qt) MIKUNI Final gear oil: Spark plug (s): Type: Manufacturer/model: SAE80 API GL-4 Hypoid gear oil NGK/CPR7EA-9 Quantity: Spark plug gap: 0.20 L (0.21 US qt) (0.18 Imp.qt) 0.8–0.9 mm (0.031–0.035 in) Differential gear oil: Clutch:...
Page 165 Caster angle: Rear: 5.0 ° 27.0 kPa (3.9 psi) (0.270 kgf/cm²) Trail: Maximum: 26.0 mm (1.02 in) Front: Front tire: 38.0 kPa (5.5 psi) (0.380 kgf/cm²) Rear: Type: 33.0 kPa (4.8 psi) (0.330 kgf/cm²) Tubeless Front wheel: Size: AT25 x 8-12 Wheel type: Manufacturer/model: Panel wheel...
Page 166 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W Type: Meter lighting: Double wishbone Spring/shock absorber type: Neutral indicator light: Coil spring/oil damper Wheel travel: Reverse indicator light: 180 mm (7.1 in) Rear suspension: Coolant temperature warning light: Type: Double wishbone Engine trouble warning light: Spring/shock absorber type: Coil spring/oil damper...
Page 167 Ignition fuse: 10.0 A Auxiliary DC jack fuse: 15.0 A Four-wheel-drive motor fuse: 10.0 A Radiator fan fuse: 15.0 A 10-5...
Page 168: Consumer Information
Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
Page 169 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 170: 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 171: 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 172: 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 173 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 174: 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 175 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 176 EBU26132 11-9...
Page 177 INDEX Differential gear oil ..........5-4, 8-29 Drive select lever ............4-16 Accessories and loading ..........6-6 Drive select lever and driving in reverse ......6-3 Accessories, auxiliary jack ........... 4-23 Drive select lever safety system cable, adjusting ..8-45 Air filter element, cleaning ..........
Page 178 Riding your ATV ............. 7-1 Key identification number ..........11-1 Safety information ............1-1 Seat ................4-19 Label locations ............... 2-1 Shock absorber assemblies, Light switch ..............4-7 adjusting the front and rear ........4-22 Low-range indicator light ..........4-3 Spark arrester, cleaning ..........
Page 179 Wheel hub bearings, checking ........8-54 Wheel, installing ............8-63 Wheel, removing ............8-62...
Page 182 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 2007.04-3.8×1 CR...

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