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Skoda - Auto - skoda-karoq-2017-110444
Skoda - Auto - skoda-karoq-2017-brukerhandbok-110449
Skoda - Auto - skoda-karoq-2017-110460
Skoda - Auto - skoda-karoq-2017-ipasnieka-rokasgramata-110447
Skoda - Auto - skoda-karoq-2017-110457
Skoda - Auto - skoda-karoq-2017-omistajan-kasikirja-110439
Skoda - Auto - skoda-karoq-2017-manual-del-propietario-110438
Skoda - Auto - skoda-karoq-2017-savininko-vadovas-110446
Cars & Automotive Accessories - Kenwood - C929
Toys & Accessories - Lego - DUPLO Town - AROUND THE WORLD - 10805
Skoda - Auto - skoda-karoq-2017-kullan-m-k-lavuzu-110458
Barossa - Motorcycle - Barossa__Barossa_PYTHON_100cc_parts_5d8a7f921c3648a62136367
Skoda - Auto - skoda-karoq-2017-navod-k-obsluze-110433
Skoda - Auto - skoda-karoq-2017-110453
Skoda - Auto - skoda-karoq-2017-handleiding-110448
Pool Equipment - Haywood-Pool - Super Pump~All Super Pump Models
Skoda - Auto - skoda-karoq-2017-prirocnik-za-lastnika-110456
Skoda - Auto - skoda-karoq-2017-110431
VCRs & Accessories - Hitachi Electronics - VTM171A
Skoda - Auto - skoda-karoq-2017-instrukcja-obslugi-110450
Skoda - Auto - skoda-karoq-2017-manualul-de-utilizare-110452
Skoda - Auto - skoda-karoq-2017-agarmanual-110454
Barossa - Motorcycle - Barossa_PYTHON_100cc_parts
1981-1995--Chrysler--Lebaron--4 Cylinders J 2.5L MFI Turbo SOHC--31034803
1981-1995--Chrysler--Lebaron--4 Cylinders C 2.2L FI Turbo SOHC--31006701
Furniture & Storage - Blue Rhino - GAD1375SP
Skoda - Auto - skoda-karoq-2017-manual-do-proprietario-110451
Barossa - Motorcycle - Barossa__Barossa_PYTHON_100cc_parts
Skoda - Auto - skoda-karoq-2017-110441
Sewing Machine - Singer - 14T968DC %7C PROFESSIONAL 5
Grills & Accessories - Blue Rhino - Blue Rhino WAD996SP
Video Cameras, Camcorders, & Accessories - Canon - ZR900 Camcorder
Cars & Automotive Accessories - Kenwood - DPX-510
Skoda - Auto - skoda-karoq-2017-manuel-du-proprietaire-110440
Skoda - Auto - skoda-karoq-2017-instruktionsbog-110435
Cameras & Accessories - Nikon - Nikon COOLPIX S203
Skoda - Auto - skoda-karoq-2017-uzivatelska-prirucka-110455
Skoda - Auto - skoda-karoq-2017-110432
Skoda - Auto - skoda-karoq-2017-kezelesi-utmutato-110443
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.6L 2BL SOHC--31218102
1981-1995--Chrysler--Lebaron--4 Cylinders B 2.2L 2BL SOHC--31218101
Skoda - Auto - skoda-karoq-2017-omaniku-kasiraamat-110436
Skoda - Auto - skoda-karoq-2017-manuale-del-proprietario-110445
Cars & Automotive Accessories - Ford - F-150 2001
Printers & Accessories - Xerox - WorkCentre Pro C2128~C2636~C3545
Skoda - Auto - skoda-karoq-2017-110459
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.2L TBI SOHC--31034802
Speaker Systems - JBL - Xtreme
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.2L TBI SOHC--31095601
Skoda - Auto - skoda-karoq-2017-owner-s-manual-110437
Speakers & Audio Accessories - Dual - Dual - SX652 ~ SX692
1981-1995--Chrysler--Lebaron--4 Cylinders J 2.5L MFI Turbo SOHC--31006702
Power Tools & Accessories - STIHL - STIHL Trimmer FS 40, FS 50
Sewing Machine - Brother - Brother BAS-511
Skoda - Auto - skoda-karoq-2017-vodic-za-korisnike-110442
Ducati - Motorcycle - Ducati_M620_ie_Parts_2002
Sewing Machine - Brother - Brother DB2-B798
Printers & Accessories - Epson - Stylus Pro 9000
DJ Equipment - Kramer AV - VM-4HDT
Printers & Accessories - Epson - WorkForce 40
Summary of Content
READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45FAV WARNING LIT-11626-19-57 This ATV should not be ridden by anyone under 16 years of age. 1D9-F8199-12 EBU00776 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00941 INTRODUCTION 1- Congratulations on your purchase of the Yamaha YFM45FAV. It 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. This manual will provide you with a good basic understanding of the features and operation of this ATV. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: ● READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. ● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. ● NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION. ● THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE. EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING CAUTION: NOTE: Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. A NOTE provides key information to make procedures easier or clearer. E_Info.fm Page 2 Monday, August 8, 2005 4:27 PM EBU15000 IMPORTANT NOTICE 1- 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. Please check your local riding laws and regulations before operating this ATV. EBU01067 AFFIX DEALER LABEL HERE YFM45FAV OWNER’S MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11626-19-57 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1 2 SAFETY INFORMATION.................. 2-1 3 DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2 Key identification number................ 3-2 Vehicle identification number .......... 3-3 Model label ...................................... 3-3 4 CONTROL FUNCTIONS .................. 4-1 Main switch...................................... 4-1 Indicator and warning lights .............4-2 Fuel gauge .......................................4-4 Speedometer unit ............................4-5 Handlebar switches .........................4-7 Throttle lever ..................................4-13 Speed limiter ..................................4-14 Front brake lever............................4-15 Brake pedal and rear brake lever .............................................4-15 Drive select lever ...........................4-16 Recoil starter..................................4-17 Fuel tank cap .................................4-18 Fuel cock........................................4-18 Starter (choke) ..............................4-20 Seat................................................4-20 Storage compartment ....................4-21 Front carrier ...................................4-22 Rear carrier ....................................4-22 Front and rear shock absorber adjustment ...................................4-23 Auxiliary DC jack............................4-25 EE.book Page 2 Friday, May 6, 2005 8:59 AM 5 6 PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-2 Fuel ................................................. 5-4 Engine oil ........................................ 5-6 Final gear oil.................................... 5-6 Differential gear oil .......................... 5-6 Coolant............................................ 5-7 Throttle lever ................................... 5-7 Fittings and fasteners...................... 5-8 Lights............................................... 5-8 Switches.......................................... 5-8 Tires ................................................ 5-8 How to measure tire pressure....... 5-10 Tire wear limit................................ 5-11 OPERATION..................................... 6-1 Starting a cold engine ..................... 6-1 Starting a warm engine................... 6-3 Warming up..................................... 6-3 Drive select lever operation and reverse driving............................... 6-4 Engine break-in............................... 6-7 Parking ............................................ 6-8 Parking on a slope........................... 6-9 Accessories and loading ............... 6-10 7 RIDING YOUR ATV .......................... 7-1 Getting to know your ATV ............... 7-3 Ride with care and good judgement...................................... 7-4 Be careful where you ride.............. 7-16 Turning your ATV .......................... 7-22 Climbing uphill ............................... 7-24 Riding downhill .............................. 7-30 Crossing a slope............................ 7-32 Crossing through shallow water .... 7-34 Riding over rough terrain............... 7-37 Sliding and skidding....................... 7-38 What to do if .................................. 7-40 What to do .................................... 7-40 EE.book Page 3 Friday, May 6, 2005 8:59 AM 8 PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1 Owner’s manual and tool kit............ 8-1 Periodic maintenance chart for the emission control system.......... 8-3 General maintenance and lubrication chart ............................. 8-4 Panel removal and installation ........ 8-6 Engine oil and oil filter cartridge .... 8-12 Final gear oil .................................. 8-17 Differential gear oil......................... 8-20 Cooling system.............................. 8-22 Changing the coolant .................... 8-24 Axle boots...................................... 8-27 Spark plug inspection.................... 8-28 Air filter element cleaning.............. 8-31 V-belt cooling duct check hose ..... 8-34 V-belt case drain plug.................... 8-34 Spark arrester cleaning ................. 8-35 Carburetor adjustment................... 8-36 Idle speed adjustment ................... 8-37 Valve clearance adjustment .......... 8-38 Throttle lever adjustment............... 8-38 Select lever safety system cable adjustment..........................8-39 Front brake pad check ...................8-39 Rear brake pad check....................8-40 Inspecting the brake fluid level ......8-41 Brake fluid replacement .................8-42 Front brake lever free play.............8-43 Adjusting the rear brake lever and brake pedal ..................................8-44 Adjusting the rear brake light switch ...........................................8-46 Cable inspection and lubrication.....................................8-47 Lubricating the brake levers and brake pedal ..................................8-47 Rear knuckle upper and lower pivot lubrication ............................8-48 Wheel removal...............................8-49 Wheel installation...........................8-49 Battery............................................8-50 Battery maintenance......................8-52 Fuse replacement ..........................8-52 Replacing a headlight bulb ............8-54 EE.book Page 4 Friday, May 6, 2005 8:59 AM Headlight beam adjustment .......... 8-57 Tail/brake light bulb replacement ................................ 8-58 Troubleshooting ............................ 8-59 Troubleshooting charts ................. 8-61 9 CLEANING AND STORAGE............ 9-1 A. Cleaning...................................... 9-1 B. Storage ....................................... 9-3 10 SPECIFICATIONS.......................... 10-1 11 NOISE REGULATION.................... 11-1 12 MAINTENANCE RECORD ............ 12-1 13 ATV LIMITED WARRANTY............ 13-1 14 YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................... 14-1 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1- 1-1 EE.book Page 2 Friday, May 6, 2005 8:59 AM 1 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 1 WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum front cargo limit of : 40kg (88 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 5ND-F4877-00 2 2 3 4 5 6 7 3 8 9 10 11 12 13 14 1-2 EE.book Page 3 Friday, May 6, 2005 8:59 AM 4 6 WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum rear cargo limit of : 80kg (176 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual. 5ND-F4897-00 5 MAXIMUM .LOADING LIMIT PULLING LOAD: TONGUE WEIGHT: 4900 1102 147 33 (500kgf) N lbf ( 15kgf) N lbf 5ND-F151K-00 1-3 EE.book Page 4 Friday, May 6, 2005 8:59 AM 7 8 WARNING UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. 9 WARNING NEVER operate this ATV if you are under age 16. Turning the ATV in 4WD-LOCK ( “DIFF. LOCK” ) takes more effort. YAMAHA 4XE-F415A-00 Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control. 5ND-F1558-00 1-4 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU13351 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: ● Read this manual and all labels carefully and follow the operating procedures described. ● Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you. ● Always follow the age recommendation: – A child under 16 years old should never operate an ATV with engine size greater than 90cc. ● Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely. ● Never carry a passenger on an ATV. ● Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. ● Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 2-1 EE.book Page 2 Friday, May 6, 2005 8:59 AM ● ● ● ● ● ● ● ● ● ● Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. 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 this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. 2-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EE.book Page 3 Friday, May 6, 2005 8:59 AM ● ● ● ● ● Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed. Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible. Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. 2-3 EE.book Page 4 Friday, May 6, 2005 8:59 AM ● ● ● ● ● ● ● Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings. Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Always use the size and type of tires specified in this manual. Always maintain proper tire pressure as described in this manual. Never modify an ATV through improper installation or use of accessories. Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344. 2-4 EE.book Page 5 Friday, May 6, 2005 8:59 AM WARNING When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel immediately after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers. 2-5 EE.book Page 6 Friday, May 6, 2005 8:59 AM WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation. 2-6 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1- 1. Rear shock absorber assembly spring preload adjusting ring 2. Spark arrester 3. Storage compartment and tool kit 4. Spark plug 5. Rear brake fluid reservoir 6. Front shock absorber assembly spring preload adjusting ring 7. Brake pedal 8. V-belt case 9. Radiator cap 10. Fuel cock 11. Air filter case 12. Fuses 13. Tail/brake light 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Engine oil dipstick Oil filter cartridge Coolant reservoir V-belt cooling duct check hose Rear brake lever Left handlebar switches Starter (choke) Drive select lever Speedometer unit Main switch Fuel tank cap Auxiliary DC jack Right handlebar switch Throttle lever Front brake lever NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual. 3-1 EE.book Page 2 Friday, May 6, 2005 8:59 AM EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: Key identification number The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key. 1 2 3 4 5 6 7 8 2. VEHICLE IDENTIFICATION NUMBER: 9 10 1. Key identification number 11 12 3. MODEL LABEL INFORMATION: 13 14 3-2 EE.book Page 3 Friday, May 6, 2005 8:59 AM EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 1. Model label 3-3 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00039 CONTROL FUNCTIONS 1- 1 WARNING 2 Indicates a potential hazard that could result in serious injury or death. 3 4 EBU09420 5 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position. 6 1. Main switch 7 8 9 10 11 12 13 14 4-1 EE.book Page 2 Friday, May 6, 2005 8:59 AM EBU08020 EBU10601 Indicator and warning lights Differential gear lock indicator light “DIFF. LOCK” This indicator light and the differential gear lock indicator in the display come on when the differential gear lock switch is set to the “4WDLOCK” position. NOTE: When the switch is set to “LOCK”, the differential gear lock indicator light will flash until the differential gear is locked. _ _ 1. 2. 3. 4. 5. 6. 7. 8. Differential gear lock indicator light “DIFF. LOCK” Low-range indicator light “L” High-range indicator light “H” Neutral indicator light “N” Reverse indicator light “R” Park indicator light “P” Differential gear lock indicator “ ” Coolant temperature warning light “ ” EBU11220 Low-range indicator light “L” This indicator light comes on when the drive select lever is in the “L” position. DIFF. LOCK EBU01064 High-range indicator light “H” This indicator light comes on when the drive select lever is in the “H” position. 4-2 EE.book Page 3 Friday, May 6, 2005 8:59 AM EBU09720 EBU11312 Neutral indicator light “N” This indicator light comes on when the drive select lever is in the “N” position. Four-wheel-drive indicator “ ”/“ ” This indicator comes on when the “2WD”/ “4WD” switch is set to the “4WD” position. The differential gear lock indicator “DIFF.LOCK” in the four-wheel-drive indicator also comes on when the “LOCK”-“4WD” switch is set to the “4WD-LOCK” position. DIFF. LOCK EBU12500 Reverse indicator light “R” This indicator light comes on when the drive select lever is in the “R” position. NOTE: Due to the synchronizing mechanism in the differential gear case, the four-wheel drive indicator may not come on until the ATV starts moving. _ EBU00609 Park indicator light “P” This indicator light comes on when the drive select lever is in the “P” (park) position. _ 4-3 EE.book Page 4 Friday, May 6, 2005 8:59 AM EBU00860 EBU00052 Coolant temperature warning light “ ” When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes. Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank. When the needle reaches the red line, refill the tank at the first opportunity. CAUTION: _ ● ● The engine may overheat if the ATV is overloaded. If this happens, reduce the load to specification. After restarting, make sure that the light is out. Continuous use while the light is on may cause damage to the engine. 1. Fuel gauge 2. Red line NOTE: If the machine runs out of fuel, move the fuel cock lever to the “RES” position. Approximately 4.5 L (0.99 Imp gal, 1.19 US gal) of fuel will be remaining in the tank. _ _ _ 4-4 EE.book Page 5 Friday, May 6, 2005 8:59 AM EBU11322 Speedometer unit ● ● ● 1. 3. 5. 6. Speedometer 2. Clock/Hour meter 4. Clock/Hour button “ “H” button 7. Odometer/Tripmeter A/Tripmeter B TRIP/ODO button ”/“ ” “M” button The speedometer unit is equipped with the following: ● a speedometer (which shows the riding speed) ● an odometer (which shows the total distance traveled) 4-5 two tripmeters (which show the distance traveled since they were last set to zero) a clock an hour meter (which shows the total time the key has been turned to “ON”) EE.book Page 6 Friday, May 6, 2005 8:59 AM Odometer and tripmeter modes Pushing the “TRIP/ODO” button switches the display between the odometer mode “ODO” and the tripmeter modes “A” and “B” in the following order: ODO→TRIP A→TRIP B→ODO To reset a tripmeter, select it by pushing the “TRIP/ODO” button, and then push the “TRIP/ ODO” button for at least three seconds. The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops. 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. Push the “ ”/“ ” button until the clock starts flashing. 3. Set the hours by pushing the “H” button. 4. Set the minutes by pushing the “M” button. 5. Push the “ ”/“ ” button, and then release it to start the clock. NOTE: Holding in the “TRIP/ODO” button and then turning the key to “ON” switches the display between “mph” and “km/h”. _ _ 4-6 EE.book Page 7 Friday, May 6, 2005 8:59 AM EBU00053 Handlebar switches CAUTION: _ Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. _ EBU12050 1. 2. 3. 4. Engine stop switch “ / ” Make sure that the engine stop switch is set to “ ” before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not start or run when the engine stop switch is set to “ ”. Light switch “ / /OFF” Start switch “ ” Engine stop switch “ / ” Override switch “OVERRIDE” EBU12040 Light switch “ / /OFF” Set the switch to “ ” to turn on the low beam and the taillight. Set the switch to “ ” to turn on the high beam and the taillight. Set the switch to “OFF” to turn off all the lights. 4-7 EE.book Page 8 Friday, May 6, 2005 8:59 AM EBU00607 Start switch “ ” The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine. (See pages 6-1–6-3 for details.) 1. Override switch “OVERRIDE” EBU13781 4-8 Override switch “OVERRIDE” Top speed is normally limited when operating in 4WD-LOCK. If conditions require more engine power when riding forward, push and hold this switch to override the 4WD-LOCK speed limiting function. (See pages 4-11–4-13 for a detailed explanation about the differential gear lock switch and its function.) Releasing the switch restores the speed limiting function. While this switch is pushed, the segments of the speedometer digits will appear as shown in the figure. EE.book Page 9 Friday, May 6, 2005 8:59 AM WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The amount of effort is more the faster you go. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in 4WD-LOCK, and allow extra time and distance for maneuvers. NOTE: If the digits of the speedometer appear as shown when the switch is NOT being pushed, this could indicate a malfunction in the electrical system. In this case, take the ATV to a Yamaha dealer at the first opportunity. _ _ 4-9 EE.book Page 10 Friday, May 6, 2005 8:59 AM ● ● 1. On-Command four-wheel drive switch “2WD”/“4WD” 2. Differential gear lock switch “LOCK”/“4WD” EBU14091 On-Command four-wheel drive and differential gear lock switches This ATV is equipped with an On-Command four-wheel drive switch “2WD”/“4WD” and a differential gear lock switch “LOCK”/“4WD”. Select the appropriate drive according to terrain and the conditions. ● Two-wheel drive (2WD): Power is supplied to the rear wheels only. 4-10 Four-wheel drive (4WD): Power is supplied to the rear and front wheels. Four-wheel drive with the differential gear locked (4WD-LOCK): Power is supplied to the rear and front wheels when the differential gear is locked (“DIFF.LOCK”). Unlike the 4WD mode, all wheels turn at the same speed. EE.book Page 11 Friday, May 6, 2005 8:59 AM WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 4WD-LOCK (“DIFF.LOCK”), or vice-versa while the ATV is moving. WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD and in 4WD-LOCK in some circumstances. Changing from 2WD to 4WD or from 4WD to 4WD-LOCK, or vice-versa while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and increase the risk of losing control and an accident. HOW TO AVOID THE HAZARD Always stop the ATV before changing from 2WD to 4WD or from 4WD to 4WD-LOCK, or vice-versa. 1. Lever 2. On-Command four-wheel drive switch “2WD”/“4WD” On-Command four-wheel drive switch “2WD”/“4WD” To change from 2WD to 4WD, stop the ATV, and then set the switch to “4WD”. When the ATV is in 4WD, the 4WD indicator “ ” will come on in the speedometer unit display. To change from 4WD to 2WD, stop the ATV, be sure the lever is set to position a, and then set the switch to “2WD”. 4-11 EE.book Page 12 Friday, May 6, 2005 8:59 AM WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The amount of effort is more the faster you go. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in 4WD-LOCK, and allow extra time and distance for maneuvers. 1. Differential gear lock switch “LOCK”/“4WD” 2. Lever Differential gear lock switch “LOCK”/ “4WD” To lock the differential gear in 4WD, make sure the On-Command four-wheel-drive switch is set to “4WD”, stop the ATV, move the lever to position b, and then set the switch to “LOCK”. When the differential gear is locked, the differential gear lock indicator (“DIFF.LOCK”) light will come on along with the indicator “ ” in the speedometer unit display. To release the differential gear lock, stop the ATV and set the switch to “4WD”. DIFF. LOCK 4-12 EE.book Page 13 Friday, May 6, 2005 8:59 AM EBU00062 NOTE: ● When the switch is set to “LOCK”, the differential gear lock indicator light will flash until the differential gear is locked. ● When the indicator light is flashing, turning the handlebar back and forth will help the differential gear lock to engage. ● Riding before the differential gear lock is properly engaged (e.g., when the indicator light is flashing) will cause the engine speed to be limited until engagement is complete. ● When the ATV is in 4WD-LOCK, the maximum traveling speed is limited to 35 km/h (22 mph). However, if conditions require full engine power to be available, push and hold the override switch to disable the 4WD-LOCK speed limiter. (See pages 4-8–4-9 for a detailed explanation of this switch.) Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. _ 1. Throttle lever _ 4-13 EE.book Page 14 Friday, May 6, 2005 8:59 AM EBU01159 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. WARNING POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. 1. Locknut 2. Adjusting screw a. No more than 12 mm (0.47 in) 4-14 EE.book Page 15 Friday, May 6, 2005 8:59 AM EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. 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). See page 8-38. 1. Front brake lever EBU00732 4-15 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. Push down on the pedal or pull the lever toward the handlebar to apply the rear brake. EE.book Page 16 Friday, May 6, 2005 8:59 AM EBU00608 Drive select lever The drive select lever is used to shift your machine into the low, high, neutral, reverse and park positions. (Refer to pages 6-4–6-6 for the drive select lever operation.) 1. Brake pedal 1. Drive select lever 1. Rear brake lever 4-16 EE.book Page 17 Friday, May 6, 2005 8:59 AM EBU00855 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out. WARNING POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position “P”. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Set the drive select lever to the park position before starting the engine. 1. Recoil starter 4-17 EE.book Page 18 Friday, May 6, 2005 8:59 AM EBU00092 EBU00930 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position, fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY. After refuelling, return the fuel cock lever to the “ON” position. 1. Fuel tank cap 4-18 EE.book Page 19 Friday, May 6, 2005 8:59 AM OFF Position RES Position 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “RES” ON Position 1. Arrow mark pointing to “ON” 4-19 EE.book Page 20 Friday, May 6, 2005 8:59 AM EBU00095 EBU05670 Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “Starting a cold engine” for proper operation. (See pages 6-1–6-3.) Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. 1. Seat 1. Starter (choke) “ ” 4-20 2. Seat lock lever EE.book Page 21 Friday, May 6, 2005 8:59 AM EBU15230 To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Storage compartment NOTE: Make sure that the seat is securely fitted. The storage compartment is located under the seat. (See pages 4-20–4-21 for seat removal and installation procedures.) When storing any documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartment. Maximum load limit: 2.0 kg (4 lb) _ _ NOTE: There is a check hose at the bottom of the storage compartment. If any water collects in this hose, remove the hose, empty it, and then install it. _ 1. Projection (× 2) 2. Seat holder (× 2) _ 4-21 EE.book Page 22 Friday, May 6, 2005 8:59 AM EBU00582 Front carrier Maximum load limit: 40 kg (88 lb) EBU00583 Rear carrier Maximum load limit: 80 kg (176 lb) 1. Storage compartment 1. Storage compartment check hose 4-22 EE.book Page 23 Friday, May 6, 2005 8:59 AM EBU15220 Front and rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b. 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. _ _ Standard position: 2 1- Minimum (soft) 5- Maximum (hard) 4-23 EE.book Page 24 Friday, May 6, 2005 8:59 AM WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting. 1. Special wrench 4-24 EE.book Page 25 Friday, May 6, 2005 8:59 AM EBU10020 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1. Set the light switch to “OFF”. 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. CAUTION: _ ● ● ● 1. Auxiliary DC jack cap 2. Start the engine. (See pages 6-1–6-3.) 3. Open the auxiliary DC jack cap, and then insert the accessory power plug into the jack. _ 4-25 Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult. Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged. EE.book Page 26 Friday, May 6, 2005 8:59 AM 1. Auxiliary DC jack EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death. 4-26 EE.book Page 1 Friday, May 6, 2005 8:59 AM 1- PRE-OPERATION CHECKS 1 Before using this machine, check the following points: 2 ITEM ROUTINE PAGE Front brake • Check operation, lever free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. 5-2–5-3, 8-39–8-43 4 Rear brake • Check operation, lever free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. 5-2–5-3, 8-40–8-42, 8-44–8-45 5 Fuel • Check fuel level. • Fill with fuel if necessary. Engine oil • Check oil level. • Fill with oil if necessary. 5-6, 8-12–8-17 Coolant reservoir • Check coolant level in reservoir. • Fill with coolant if necessary. 5-7, 8-22–8-27 9 Final gear oil and differential gear oil • Check for leakage. 5-6, 8-17–8-22 10 Throttle • Check for proper throttle cable operation and free play. 5-7, 8-38 11 Wheels and tires • Check tire pressure, wear and damage. 5-8–5-11, 8-49–8-50 12 Fittings and fasteners • Check all fittings and fasteners. Lights and switches • Check for proper operation. Axle boots • Check for damage. 5-4–5-5 3 6 7 5-8 5-8, 8-46, 8-54–8-59 8-27–8-28 5-1 8 13 14 EE.book Page 2 Friday, May 6, 2005 8:59 AM EBU11011 Front and rear brakes Brake levers and brake pedal ● Check that there is no free play in the front brake lever. If there is free play, have a Yamaha dealer adjust it. ● Check for correct free play in the rear brake lever. If the free play is incorrect, adjust it. (See pages 8-44–8-45.) ● Check for correct brake pedal height. If the pedal height is incorrect, have a Yamaha dealer adjust it. ● Check the operation of the brake levers and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have a Yamaha dealer inspect the brake system. 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 the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. Brake fluid level Check the brake fluid level. Add fluid if necessary. (See pages 8-41–8-42.) Recommended brake fluid: DOT 4 5-2 EE.book Page 3 Friday, May 6, 2005 8:59 AM Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be inspected by a Yamaha dealer. WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have a Yamaha dealer check for the cause. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brake pads for wear. (See pages 8-39–8-40.) 5-3 EE.book Page 4 Friday, May 6, 2005 8:59 AM EBU01085 Fuel Make sure there is sufficient gasoline in the tank. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total: 15.0 L (3.30 Imp gal, 3.96 US gal) Reserve: 4.5 L (0.99 Imp gal, 1.19 US gal) CAUTION: _ Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. _ 5-4 EE.book Page 5 Friday, May 6, 2005 8:59 AM Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. 1. Fuel level WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot. 2. Fuel tank filler tube 5-5 EE.book Page 6 Friday, May 6, 2005 8:59 AM EBU10842 EBU00493 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-12– 8-17.) Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-17– 8-20 for details.) CAUTION: Recommended oil: SAE 80 API GL-4 Hypoid gear oil _ ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase. If desired, an SAE 80W90 hypoid gear oil may be used for all conditions. NOTE: GL-4 is a quality and additive rating, GL-5 or GL-6 rated hypoid gear oils may also be used. EBU00678 Differential gear oil Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-20–8-22 for details.) _ Recommended engine oil type and quantity: See page 10-2. Recommended oil: SAE 80 API GL-4 Hypoid gear oil 5-6 EE.book Page 7 Friday, May 6, 2005 8:59 AM EBU12530 Coolant Check the coolant level in the coolant reservoir when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir. If the coolant level is at or below the minimum level mark, add distilled water to bring the level up to maximum level mark. Change the coolant every two years. (See pages 8-22–8-27 for details.) 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 the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. CAUTION: _ Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. EBU01083 _ Throttle lever Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation. Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.22 Imp qt, 0.26 US qt) 5-7 EE.book Page 8 Friday, May 6, 2005 8:59 AM EBU11620 EBU00157 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD 1. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recommended. EBU10030 Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation. EBU11700 Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation. ACE-01E Manufacturer 5-8 Size Type Front MAXXIS AT25 × 8-12 M911Y Rear MAXXIS AT25 × 10-12 M912Y EE.book Page 9 Friday, May 6, 2005 8:59 AM 2. The tires should be set to the recommended pressure: ● Recommended tire pressure Front 25 kPa (0.25 kgf/cm2, 3.6 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) ● Check and adjust tire pressures when the tires are cold. ● Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 22 kPa (0.22 kgf/cm2, 3.2 psi) Rear 22 kPa (0.22 kgf/cm2, 3.2 psi) 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. 5-9 EE.book Page 10 Friday, May 6, 2005 8:59 AM EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure with tires cold. Set tire pressures to the following specifications: ACE-02EACE-02E Recommended pressure Minimum Maximum Front 25 kPa (0.25 kgf/cm2, 3.6 psi) 22 kPa (0.22 kgf/cm2, 3.2 psi) 28 kPa (0.28 kgf/cm2, 4.0 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) 22 kPa (0.22 kgf/cm2, 3.2 psi) 28 kPa (0.28 kgf/cm2, 4.0 psi) 1. Low-pressure tire gauge 5-10 EE.book Page 11 Friday, May 6, 2005 8:59 AM EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit 5-11 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00161 EBU15111 OPERATION Starting a cold engine 1- WARNING WARNING POTENTIAL HAZARD Freezing control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding. Indicates a potential hazard that could result in serious injury or death. WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer. 1. Apply the rear brake lever. 2. Turn the fuel cock to “ON”. 3. Turn the main switch to “ON” and the engine stop switch to “ ”. 4. Shift the drive select lever into the neutral or park position. 6-1 EE.book Page 2 Friday, May 6, 2005 8:59 AM Position 3 : Cold engine startambient temperature above 25 °C (80 °F) and warm engine start position. NOTE: ● When the drive select lever is in the neutral or park position, if either indicator light does not come on, ask a Yamaha dealer to inspect the respective electric circuit. ● The engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral or park before starting the engine. _ 1 2 3 4 5 6 _ 7 5. Use the starter (choke) in reference to the figure: Position 1 : Cold engine startambient temperature below 5 °C (40 °F). Position 2 : Cold engine startambient temperature at 0 °C (30 °F)–30 °C (90 °F) and warming up position. 8 9 10 a. Starter (choke) 2. Half open 1. Fully open 3. Closed 6. Completely close the throttle lever and start the engine by pushing the start switch. 6-2 11 12 13 14 EE.book Page 3 Friday, May 6, 2005 8:59 AM NOTE: ● If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. ● If the battery is discharged, pull the recoil starter to start the engine. CAUTION: _ _ See the “Engine break-in” section prior to operating the engine for the first time. _ EBU00180 Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly. _ 7. If the engine is started with the starter (choke) in position 1, the starter (choke) should be returned to position 2 to warm up the engine. If the engine is started with the starter (choke) in position 2, keep the starter (choke) in this position to warm up the engine. 8. Continue warming up the engine until it idles smoothly and return the starter (choke) to position 3 before riding. EBU00182 Warming up To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off. 6-3 EE.book Page 4 Friday, May 6, 2005 8:59 AM EBU08461 Drive select lever operation and reverse driving CAUTION: _ Before shifting, you must stop the ATV and return the throttle lever to the closed position, otherwise the transmission may be damaged. _ Shifting: Neutral to High and High to Low 1. Bring the ATV to a complete stop and return the throttle lever to the closed position. 2. Apply the brakes, then shift by moving the drive select lever along the shift guide. 1. Drive select lever 3. Open the throttle lever gradually. NOTE: Make sure that the drive select lever is completely shifted into position. _ _ 6-4 EE.book Page 5 Friday, May 6, 2005 8:59 AM Shifting: Neutral to Reverse and Reverse to Park NOTE: The drive select lever cannot be shifted into or from reverse or park without applying the rear brake. _ _ 1. Bring the ATV to a complete stop and return the throttle lever to the closed position. 2. Apply the brake pedal. 3. Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide. 1. Drive select lever NOTE: ● When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the electrical circuit. ● Due to the synchronizing mechanism in the engine, the light may not come on until the ATV starts moving. _ _ 4. Check behind for people or obstacles, and then release the brake pedal. 6-5 EE.book Page 6 Friday, May 6, 2005 8:59 AM 5. Open the throttle lever gradually and continue to watch to the rear while backing. WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly. 6-6 EE.book Page 7 Friday, May 6, 2005 8:59 AM EBU02101 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided. However, momentary (2–3 seconds maximum) full throttle operation under load does not harm the engine. Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer. 0–10 hours: Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to time. Do not operate it at one set throttle position. 6-7 EE.book Page 8 Friday, May 6, 2005 8:59 AM EBU00612 10–20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time. Parking When parking, stop the engine and shift the drive select lever into the park position, then turn the fuel cock to the “OFF” position. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally. 6-8 EE.book Page 9 Friday, May 6, 2005 8:59 AM EBU06151 Parking on a slope 1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the brake pedal applied, shift the drive select lever to the park position “P”. WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the machine transversely across the incline, apply the parking brake, and block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily. 6-9 EE.book Page 10 Friday, May 6, 2005 8:59 AM EBU00221 Accessories and loading ● EBU00222 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market. However, it is not possible for Yamaha to test all non-Yamaha accessories, nor have any control over the quality or suitability of them. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality. ● ● 6-10 Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV. Do not mount an accessory where it could interfere with your ability to control the ATV. Examples include (but are not limited to) a heavy or bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view. Use extra caution when riding an ATV with accessories. The ATV may handle differently than it does without accessories. EE.book Page 11 Friday, May 6, 2005 8:59 AM EBU15260 Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable. ● MAXIMUM LOADING LIMIT ● Vehicle loading limit (total weight of cargo, rider and accessories, and tongue weight): 210 kg (463 lb) ● Front carrier: 40 kg (88 lb) ● Rear carrier: 80 kg (176 lb) ● Storage compartment: 2.0 kg (4 lb) ● Trailer hitch: Pulling load (total weight of trailer and cargo): 500 kgf (1,102 lbf) Tongue weight (vertical weight on trailer hitch point): 15 kgf (33 lbf) ● ● ● 6-11 Do not exceed the maximum tongue weight. You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Adjust the load in the trailer, if necessary, to reduce the weight on hitch. If you are carrying cargo and towing a trailer, include the tongue weight in the maximum vehicle load limit. Load cargo on the carrier as close to the center of the vehicle as possible. Put cargo at the rear of the front carrier and at the front of the rear carrier. Center the load from side to side. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. Make sure the load does not interfere with controls or your ability to see where you are going. EE.book Page 12 Friday, May 6, 2005 8:59 AM ● ● ● ● Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. 6-12 EE.book Page 13 Friday, May 6, 2005 8:59 AM EBU15480 WARNING _ Indicates a potential hazard that could result in serious injury or death. 6-13 EE.book Page 1 Friday, May 6, 2005 8:59 AM Riding 1- Your ATV 7-1 7 EE.book Page 3 Friday, May 6, 2005 8:59 AM WARNING _ Indicates a potential hazard that could result in serious injury or death. Owner’s Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 2-1–2-6. Please also read all caution and warning labels on your ATV. GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Riding your new ATV can be a very enjoyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely. Before you begin to ride, be sure you have read this 7-3 EE.book Page 4 Friday, May 6, 2005 8:59 AM RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the ATV’s handling and performance characteristics. Riding your ATV requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. 7-4 EE.book Page 5 Friday, May 6, 2005 8:59 AM Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc. 7-5 EE.book Page 6 Friday, May 6, 2005 8:59 AM This ATV is designed to carry operator and cargo only – passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers. 7-6 EE.book Page 7 Friday, May 6, 2005 8:59 AM Apparel Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. 7-7 EE.book Page 8 Friday, May 6, 2005 8:59 AM Do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. 7-8 EE.book Page 9 Friday, May 6, 2005 8:59 AM Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner’s Manual for this vehicle on pages 5-8–5-9. Always maintain proper tire pressure as described in the Owner’s Manual on page 5-10. 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 the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. 7-9 EE.book Page 10 Friday, May 6, 2005 8:59 AM Speed limiter For riders less experienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. Turning the adjusting screw in decreases top speed and turning it out increases top speed. (See pages 4-14–4-15 for details.) WARNING _ Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. 1. Locknut 7-10 2. Adjusting screw EE.book Page 11 Friday, May 6, 2005 8:59 AM Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads. WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owner’s Manual for carrying cargo or pulling a trailer. MAXIMUM LOADING LIMIT ● Vehicle loading limit: 210 kg (463 lb) * Total weight of cargo, rider and accessories, and trailer hitch vertical load. ● Front carrier: 40 kg (88 lb) ● Rear carrier: 80 kg (176 lb) ● Storage compartment: 2.0 kg (4 lb) ● Trailer hitch: Pulling load: 500 kgf (1,102 lbf) Total weight of trailer and cargo. Tongue weight: 15 kgf (33 lbf) Vertical weight on trailer hitch point. 7-11 EE.book Page 12 Friday, May 6, 2005 8:59 AM During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation. 7-12 EE.book Page 13 Friday, May 6, 2005 8:59 AM Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off. 7-13 EE.book Page 14 Friday, May 6, 2005 8:59 AM Modifications WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. 7-14 EE.book Page 15 Friday, May 6, 2005 8:59 AM 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. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire. Someone touching the exhaust system during or after operation could be burned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material. 7-15 EE.book Page 16 Friday, May 6, 2005 8:59 AM BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. 7-16 EE.book Page 17 Friday, May 6, 2005 8:59 AM Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways. 7-17 EE.book Page 18 Friday, May 6, 2005 8:59 AM 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. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. 7-18 EE.book Page 19 Friday, May 6, 2005 8:59 AM WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. 7-19 EE.book Page 20 Friday, May 6, 2005 8:59 AM When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles. 7-20 EE.book Page 21 Friday, May 6, 2005 8:59 AM With the engine idling, shift the drive select lever to the low position “L” or the high position “H”. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. Improper use of the brakes can cause the tires to lose traction, reducing control and increasing the possibility of an accident. Shift to the parking position “P” and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. CAUTION: _ Do not shift from drive position low “L” to high “H” or vice versa without coming to a complete stop. Damage to the engine or drive train may occur. _ 7-21 EE.book Page 22 Friday, May 6, 2005 8:59 AM TURNING YOUR ATV To achieve maximum traction while riding offroad in 2WD or 4WD, the two rear wheels turn together at the same speed. Furthermore, when riding in 4WD-LOCK (“DIFF. LOCK”), the front wheels also turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions. Operate at a slow speed and allow extra time and distance for maneuvers when in 4WD-LOCK (“DIFF. LOCK”). As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the outside of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even speed through the turn. This maneuver will let the wheel on the inside of the turn slip slightly, allowing the ATV to make the turn properly. WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. 7-22 EE.book Page 23 Friday, May 6, 2005 8:59 AM Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesn’t turn, come to a stop and then practice the procedure again. If the riding surface is slippery or loose, it may help to position more of your weight over the front wheels by moving forward on the seat. 7-23 EE.book Page 24 Friday, May 6, 2005 8:59 AM CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills. It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars. WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. 7-24 EE.book Page 25 Friday, May 6, 2005 8:59 AM WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed. 7-25 EE.book Page 26 Friday, May 6, 2005 8:59 AM If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. 7-26 EE.book Page 27 Friday, May 6, 2005 8:59 AM When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. 7-27 EE.book Page 28 Friday, May 6, 2005 8:59 AM the front and rear brakes gradually, or dismount the ATV immediately on the uphill side. If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Shift to the parking position “P” after you are stopped. If you start to roll backwards, DO NOT apply either brake abruptly. If you are in 2WD, apply only the front brake. When this ATV is in 4WD or 4WD-LOCK, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the downhill side. Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground. The ATV could easily tip over backwards. Apply both 7-28 EE.book Page 29 Friday, May 6, 2005 8:59 AM If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. When fully stopped, shift to the parking position “P”. 4WD or 4WD-LOCK: Apply both front and rear brakes gradually. When fully stopped, shift to the parking position “P”. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s Manual. 7-29 EE.book Page 30 Friday, May 6, 2005 8:59 AM RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, select low range “L” and change to 4WD or 4WD-LOCK before beginning to descend the hill. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this ATV is in 4WD or 4WD-LOCK, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the downhill side. Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground. Apply both the front and rear brakes gradually. Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear. 7-30 EE.book Page 31 Friday, May 6, 2005 8:59 AM WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this Owner’s Manual. Note: a special technique is required when braking as you go down a hill. HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. 7-31 EE.book Page 32 Friday, May 6, 2005 8:59 AM CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes be sure not to make sharp turns either up or down hill. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel. 7-32 EE.book Page 33 Friday, May 6, 2005 8:59 AM 7-33 EE.book Page 34 Friday, May 6, 2005 8:59 AM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) 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. Drive slowly and carefully. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings. WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual. 7-34 EE.book Page 35 Friday, May 6, 2005 8:59 AM Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the storage compartment check hose. Also, remove the V-belt case drain plug to drain any water that may have accumulated. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. _ 1. Air filter case check hose 7-35 EE.book Page 36 Friday, May 6, 2005 8:59 AM 1. V-belt cooling duct check hose (left front side of ATV) 1. Storage compartment check hose 1. Drive select lever box check hose 1. V-belt case drain plug 7-36 EE.book Page 37 Friday, May 6, 2005 8:59 AM RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. WARNING POTENTIAL HAZARD Improperly operating over obstacles. 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 obstacles. 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. 7-37 EE.book Page 38 Friday, May 6, 2005 8:59 AM SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide. 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. 7-38 EE.book Page 39 Friday, May 6, 2005 8:59 AM With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. 7-39 EE.book Page 40 Friday, May 6, 2005 8:59 AM WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. ● WHAT TO DO ... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-22–7-23.) ● If your ATV begins to tip while turning: Lean more into the turn to regain balance. If necessary, gradually let off the throttle and/ or steer to the outside of the turn. (See pages 7-22–7-23.) ● 7-40 If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See pages 7-38–7-39.) If your ATV can’t make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE - the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See pages 7-24–7-29.) EE.book Page 41 Friday, May 6, 2005 8:59 AM ● ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32– 7-33.) If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See pages 7-34–7-36.) WARNING _ Indicates a potential hazard that could result in serious injury or death. 7-41 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Have a Yamaha dealer perform service if you are not familiar with machine service. 1- Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages. EBU14510 Owner’s manual and tool kit You are recommended to put this owner’s manual in the vinyl bag and always carry it on the bottom of the seat as shown. Put the owner’s tool kit and low-pressure tire gauge under the seat. WARNING POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or can start fires. HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified. 1. Owner’s manual 2. Owner’s tool kit 3. Low-pressure tire gauge 8-1 EE.book Page 2 Friday, May 6, 2005 8:59 AM The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the Owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer. NOTE: If you do not have a torque wrench available during a service operation requiring one, take your machine to a Yamaha dealer to check the torque settings and adjust them as necessary. _ _ 8-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EE.book Page 3 Friday, May 6, 2005 8:59 AM EBU15731 Periodic maintenance chart for the emission control system NOTE: _ ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. How- ever, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. _ ITEM Fuel line* Valves* Spark plug Carburetor* Crankcase breather system* Exhaust system* Spark arrester Whichever month comes first km (mi) hours ROUTINE • • • • • • • • • • • • • • • Check fuel hose for cracks or damage. Replace if necessary. Check valve clearance. Adjust if necessary. Check condition. Adjust gap and clean. Replace if necessary. Check starter (choke). Adjust engine idling speed. Check breather hose for cracks or damage. Replace if necessary. Check for leakage. Tighten if necessary. Replace gasket(s) if necessary. Clean. 8-3 1 320 (200) 20 INITIAL 3 1,300 (800) 80 6 2,500 (1,600) 160 EVERY 6 12 2,500 5,000 (1,600) (3,200) 160 320 EE.book Page 4 Friday, May 6, 2005 8:59 AM EBU15720 General maintenance and lubrication chart ITEM Air filter element Engine oil Engine oil filter cartridge Engine oil strainer* Final gear oil Differential gear oil Cooling system Front brake* Rear brake* Select lever safety system cable* V-belt* Wheels* Wheel bearing* Front and rear suspension* Steering system* Whichever month comes first km (mi) hours ROUTINE • • • • • Clean. Replace if necessary. Replace. (Warm engine before draining.) Replace. Clean. • • • • • • • • • • • • • • • • • • • • • Check oil level/oil leakage. Replace every 12 months. Check coolant leakage. Repair if necessary. Replace coolant every 24 months. Check operation/fluid leakage. (See NOTE page 8-5.) Correct if necessary. Check operation/fluid leakage. (See NOTE page 8-5.) Correct if necessary. Check operation. Adjust if necessary. Check operation. Check for cracks or damage. Check balance/damage/runout. Repair if necessary. Check bearing assemblies for looseness/damage. Replace if damaged. Check operation. Correct if necessary. Check operation./Replace if damaged. Check toe-in./Adjust if necessary. 8-4 1 320 (200) 20 INITIAL EVERY 3 6 6 12 1,300 2,500 2,500 5,000 (800) (1,600) (1,600) (3,200) 80 160 160 320 Every 20–40 hours (More often in wet or dusty areas.) EE.book Page 5 Friday, May 6, 2005 8:59 AM ITEM Rear upper and lower knuckle pivots* Drive shaft universal joint* Engine mount* Front and rear axle boots* Stabilizer bushes* Fittings and fasteners* Lights and switches* Whichever month comes first km (mi) hours ROUTINE 1 320 (200) 20 INITIAL 3 1,300 (800) 80 6 2,500 (1,600) 160 EVERY 6 12 2,500 5,000 (1,600) (3,200) 160 320 • Lubricate with lithium-soap-based grease. • • • • • • • • • Lubricate with lithium-soap-based grease. Check for cracks or damage. Check operation. Replace if damaged. Check for cracks or damage. Check all chassis fittings and fasteners. Correct if necessary. Check operation. Adjust headlight beams. NOTE: ● Recommended brake fluid: DOT 4 ● Brake fluid replacement: • When disassembling the master cylinders or calipers, replace the brake fluid. Normally check the brake fluid level and add fluid as required. • On the inner parts of the master cylinders and calipers, replace the oil seals every two years. • Replace the brake hoses every four years, or if cracked or damaged. WARNING _ Indicates a potential hazard that could result in serious injury or death. 8-5 EE.book Page 6 Friday, May 6, 2005 8:59 AM EBU00614 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled. 1. Panel C 3. Panel E 1. Panel A 2. Panel B 8-6 2. Panel D 4. Panel F EE.book Page 7 Friday, May 6, 2005 8:59 AM EBU00700 Panel A, D To remove 1. Remove the seat. 2. Pull outward on the areas shown, and then pull upward. 8-7 EE.book Page 8 Friday, May 6, 2005 8:59 AM To install 1. Place the panel in its original position. 2. Install the seat. 8-8 EE.book Page 9 Friday, May 6, 2005 8:59 AM EBU01147 EBU15370 Panel B To remove Remove the bolt, and then take the panel off. To install Place the panel in the original position and install the bolt. Panel C To remove 1. Remove the top carrier bolts. CAUTION: _ When installing the panel, be sure not to pinch the cables or wires. _ 1. Carrier bolt (× 4) (top) 2. Remove the carrier bolts under the fenders, and then take the carrier off. 1. Bolt 2. Panel B 8-9 EE.book Page 10 Friday, May 6, 2005 8:59 AM To install 1. Place the panel in the original position, and then install the quick fastener screws. 2. Place the carrier in the original position, and then install the carrier bolts under the fenders. 3. Install the top carrier bolts, and then tighten all bolts to the specified torques. 1. Bolt (× 2) (under fenders) Tightening torque: Carrier bolt (top): 34 Nm (3.4 m·kgf, 24 ft·lbf) Carrier bolt (under fenders): 7.0 Nm (0.7 m·kgf, 5.1 ft·lbf) 3. Remove the quick fastener screws, and then pull the panel upward to remove. 1. Quick fastener screw (× 2) 2. Panel C 8-10 EE.book Page 11 Friday, May 6, 2005 8:59 AM EBU01013 EBU00638 Panel E To remove Remove the bolts, and then take the panel off. To install Place the panel in the original position, and then install the bolts. Panel F To remove Pull outward on the areas shown. 1. Panel F 1. Panel E 2. Bolt (× 3) 8-11 EE.book Page 12 Friday, May 6, 2005 8:59 AM EBU10992 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. To install Place the panel in its original position. To check the engine oil level 1. Remove panel F. (See pages 8-11–8-12 for panel removal and installation procedures.) 2. Place the ATV on a level surface. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Wait a few minutes until the oil settles. 5. Remove the engine oil filler cap and wipe off the dipstick with a clean rag. 8-12 EE.book Page 13 Friday, May 6, 2005 8:59 AM 1. Maximum level mark 1. Engine oil filler cap 6. Insert the dipstick in the oil filler hole (without screwing it in), and then remove it again to check the oil level. 2. Minimum level mark 7. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 8. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. 9. Install the panel. NOTE: The engine oil should be between the minimum and maximum level marks. _ _ 8-13 EE.book Page 14 Friday, May 6, 2005 8:59 AM NOTE: Skip steps 5–9 if the oil filter cartridge is not being replaced. To change the engine oil (with or without oil filter cartridge replacement) 1. Remove panel F. (See pages 8-11–8-12 for panel removal and installation procedures.) 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap. 4. Remove the engine oil drain bolt to drain the oil from the crankcase. _ _ 5. Remove panels D and E. (See pages 8-7–8-8, 8-11 for panel removal and installation procedures.) 6. Remove the oil filter cartridge with an oil filter wrench. 1. Engine oil filter cartridge 1. Engine oil drain bolt 8-14 EE.book Page 15 Friday, May 6, 2005 8:59 AM 1. Oil filter wrench 1. O-ring NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. _ _ 7. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) NOTE: Make sure the O-ring is seated properly. _ _ 8-15 EE.book Page 16 Friday, May 6, 2005 8:59 AM Recommended engine oil: See page 10-2. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.02 Imp qt, 2.43 US qt) With oil filter cartridge replacement: 2.40 L (2.11 Imp qt, 2.54 US qt) CAUTION: 1. Torque wrench _ ● 9. Install panels E and D. 10. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 11. Add the specified amount of recommended engine oil, and then install the engine oil filler cap and tighten it. ● _ 8-16 In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase. EE.book Page 17 Friday, May 6, 2005 8:59 AM EBU15380 Final gear oil Checking the final gear oil level 1. Place the ATV on a level surface. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. 12. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage is found, turn the engine off immediately and check for the cause. 13. Turn the engine off, and then check the oil level and correct it if necessary. 14. Install panel F. NOTE: The oil level should be at the brim of the filler hole. _ _ 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 8-17 1. Final gear oil filler bolt 3. Final gear oil 2. Correct oil level EE.book Page 18 Friday, May 6, 2005 8:59 AM Changing the final gear oil 1. Remove the engine guard and the final gear case guard by removing the bolts. CAUTION: _ Be sure no foreign material enters the final gear case. _ 4. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 1. Engine guard 3. Bolt (× 11) 2. Final gear case guard 2. Place the ATV on a level surface. 3. Place a container under the final gear case to collect the used oil. 8-18 EE.book Page 19 Friday, May 6, 2005 8:59 AM 6. Add the recommended final gear oil to the brim of the filler hole. 4. Remove the oil filler bolt and the drain bolt to drain the oil. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.16 L (0.14 Imp qt, 0.17 US qt) CAUTION: _ Be sure no foreign material enters the final gear case. _ 7. Install the oil filler bolt, and then tighten it to the specified torque. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) Tightening torque: Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 8. Check for oil leakage. If oil leakage is found, check for the cause. 8-19 EE.book Page 20 Friday, May 6, 2005 8:59 AM EBU07063 Differential gear oil Checking the differential gear oil 1. Place the ATV on a level surface. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to the brim of the filler hole. If the level is low, add sufficient oil of the recommended type to raise it to the specified level. 9. Install the engine guard and the final gear case guard by installing the bolts, and then tightening them to the specified torques. Tightening torques: Engine guard bolt: 7.0 Nm (0.7 m·kgf, 5.1 ft·lbf) Final gear case guard bolt: 7.0 Nm (0.7 m·kgf, 5.1 ft·lbf) 1. Differential gear oil 2. Differential gear oil filler bolt 3. Correct oil level 8-20 EE.book Page 21 Friday, May 6, 2005 8:59 AM CAUTION: _ Be sure no foreign material enters the differential gear case. _ 3. Install the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 1. Differential gear oil drain bolt 4. Install the differential gear oil drain bolt and tighten it to the specified torque. Replacing the differential gear oil 1. Place the ATV on a level surface. 2. Place a container under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil. Tightening torque: Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 5. Fill the differential gear case with the recommended oil. 8-21 EE.book Page 22 Friday, May 6, 2005 8:59 AM EBU12560 Cooling system 1. Place the ATV on a level surface. 2. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.23 L (0.20 Imp qt, 0.24 US qt) CAUTION: NOTE: The coolant should be between the minimum and maximum level marks. _ _ Be sure no foreign material enters the differential gear case. _ _ 6. Install the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7. Check for oil leakage. If oil leakage is found, check for the cause. 1. Coolant reservoir cap 2. Maximum level mark 8-22 3. Minimum level mark EE.book Page 23 Friday, May 6, 2005 8:59 AM 3. If the coolant is at or below the minimum level mark, remove panel D (See pages 8-7–8-8 for panel removal and installation procedures.), remove the reservoir cap, add coolant to the maximum level mark, install the reservoir cap, and then install the panel. NOTE: ● If water is added, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible. ● The radiator fan operation is completely automatic. It is switched on or off according to the coolant temperature in the radiator. _ Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.22 Imp qt, 0.26 US qt) _ If your ATV overheats, see page 8-62 for details. CAUTION: _ Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. _ 8-23 EE.book Page 24 Friday, May 6, 2005 8:59 AM EBU12572 Changing the coolant 1. Place the ATV on a level surface. 2. Remove panels E and F. (See pages 8-11–8-12 for panel removal and installation procedures.) 3. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object as shown to prevent coolant from spilling on the footrest.) 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 the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. 1. Coolant drain bolt 8-24 EE.book Page 25 Friday, May 6, 2005 8:59 AM 5. Remove the radiator cap. 1. Trough 4. Remove the front carrier and panel C. (See pages 8-9–8-10 for removal and installation procedures.) 1. Radiator cap 6. Remove panel D. (See pages 8-7–8-8 for panel removal and installation procedures.) 7. Remove the coolant reservoir cap. 8. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 8-25 EE.book Page 26 Friday, May 6, 2005 8:59 AM 11. Install the coolant reservoir hose. 12. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap and panel D. 13. Pour the recommended coolant into the radiator until it is full, and then install the radiator cap. Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. Antifreeze and water mixing ratio: 1:1 Total amount: 1.30 L (1.14 Imp qt, 1.37 US qt) Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.22 Imp qt, 0.26 US qt) 1. Coolant reservoir hose 9. After draining the coolant, thoroughly flush the cooling system with clean tap water. 10. Replace the coolant drain bolt washer if it is damaged, install the coolant drain bolt, and then tighten it to the specified torque. Tightening torque: Coolant drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 8-26 EE.book Page 27 Friday, May 6, 2005 8:59 AM EBU00862 Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. CAUTION: _ Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. _ 14. Start the engine and let it idle for several minutes. Stop the engine, and then check the coolant level in the radiator. If it is low, add more coolant until it reaches the top of the radiator. 15. Check for coolant leakage. NOTE: If any leakage is found, have a Yamaha dealer check the cooling system. _ 1. Front axle boot (× 2 each side) _ 16. Install the panels and the front carrier. 8-27 EE.book Page 28 Friday, May 6, 2005 8:59 AM EBU00864 Spark plug inspection Removal 1. Remove panel A. (See pages 8-7–8-8 for panel removal and installation procedures.) 2. Remove the spark plug cap. 1. Rear axle boot (× 2 each side) 1. Spark plug cap 8-28 EE.book Page 29 Friday, May 6, 2005 8:59 AM Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown. Specified spark plug: DR8EA (NGK) 1. Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator around the center electrode is a medium-to-light tan color for a ATV that is being ridden normally. Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) 8-29 EE.book Page 30 Friday, May 6, 2005 8:59 AM NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. _ _ 4. Install the spark plug cap. 5. Install the panel. a. Spark plug gap 2. Clean the gasket surface. Wipe off any grime from the threads. 3. Install the spark plug and tighten it to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) 8-30 EE.book Page 31 Friday, May 6, 2005 8:59 AM EBU15140 Air filter element cleaning 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 filter case. _ _ 1. Fastener (× 4) 2. Air filter case cover 3. Remove the air filter element assembly. 1. Air filter case check hose 1. Remove the seat. (See pages 4-20–4-21 for seat removal and installation procedures.) 2. Remove the air filter case cover by unhooking the fasteners. 1. Air filter element assembly 8-31 EE.book Page 32 Friday, May 6, 2005 8:59 AM 4. Pull off the lock plate, and then remove the air filter element from its frame. 1. Air filter element frame 3. Lock plate WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. 6. Squeeze the excess solvent out of the air filter element and let it dry. 2. Air filter element 5. Wash the element gently but thoroughly in solvent. CAUTION: _ Do not twist the air filter element when squeezing it. _ 7. Inspect the air filter element and replace it if damaged. 8-32 EE.book Page 33 Friday, May 6, 2005 8:59 AM NOTE: The air filter element should be cleaned every 20–40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet to the filter case for obstructions. Check the air filter case rubber joint to the carburetor and manifold fittings for an airtight seal. Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine. 8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element. _ NOTE: The air filter element should be wet but not dripping. _ _ 9. Pull the air filter element over its frame, and then install the lock plate. 10. Install the air filter element assembly. 11. Install the air filter case cover by hooking the fasteners onto the air filter case. 12. Install the seat. _ CAUTION: _ Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating. _ 8-33 EE.book Page 34 Friday, May 6, 2005 8:59 AM EBU06411 EBU08741 V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it. V-belt case drain plug After riding in water deep enough to allow it to enter the V-belt case, remove this plug to drain the water from the case. NOTE: If water drains from the V-belt case after removing the plug, have a Yamaha dealer inspect the ATV as the water may affect other engine parts. _ _ 1. V-belt cooling duct check hose (left front side of ATV) 1. V-belt case drain plug 8-34 EE.book Page 35 Friday, May 6, 2005 8:59 AM EBU13581 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 1. Tailpipe 2. Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install and tighten the bolts. 1. Bolt (× 3) 2. Tailpipe 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 8-35 EE.book Page 36 Friday, May 6, 2005 8:59 AM EBU00296 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine. WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. 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. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the exhaust system. CAUTION: The carburetor was set at the Yamaha factory after many tests. If the settings are disturbed by someone without sufficient technical knowledge, poor engine performance and damage may result. 8-36 EE.book Page 37 Friday, May 6, 2005 8:59 AM EBU12580 Idle speed adjustment 3. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in direction a to increase the engine speed, and in direction b to decrease the engine speed. NOTE: A diagnostic tachometer must be used for this procedure. _ _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Remove panel D. (See pages 8-7–8-8 for removal and installation procedures.) Specified idle speed: 1,450–1,550 r/min 1. Throttle stop screw 4. Install the panel. 8-37 EE.book Page 38 Friday, May 6, 2005 8:59 AM EBU00303 EBU00307 Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3.0–5.0 mm (0.12– 0.20 in). 3. Tighten the locknut. 1. Locknut a. Throttle lever free play 8-38 2. Adjusting bolt EE.book Page 39 Friday, May 6, 2005 8:59 AM EBU03050 EBU13090 Select lever safety system cable adjustment The select lever safety system cable stretches with use, resulting in improper function. To prevent this, the cable must be adjusted regularly. This adjustment, however, should be left to a Yamaha dealer. Front brake pad check Check the brake pads for damage and wear. If a brake pad thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the pads as a set. a. Brake pad thickness NOTE: The wheels need to be removed to check the brake pads. (See pages 8-49–8-50 for removal and installation procedures.) _ _ 8-39 EE.book Page 40 Friday, May 6, 2005 8:59 AM EBU06212 NOTE: The wheels need to be removed to check the brake pads. (See pages 8-49–8-50 for wheel removal and installation procedures.) Rear brake pad check Check the brake pads for damage or wear. Wear indicator grooves are provided on the brake pads. These indicators allow checking of brake pad wear without disassembling the brake. Check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, ask a Yamaha dealer to replace the pads as a set. _ _ 1. Brake pad wear indicator groove 8-40 EE.book Page 41 Friday, May 6, 2005 8:59 AM EBU06221 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish when necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. The rear brake fluid master cylinder reservoir is located under panel C. (See pages 8-9–8-10 for panel removal and installation procedures.) FRONT 1. Minimum level mark REAR 1. Minimum level mark 8-41 EE.book Page 42 Friday, May 6, 2005 8:59 AM Observe these precautions: ● When checking the fluid level, make sure the top of the master cylinder reservoirs are level. ● Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. ● ● EBU11860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. ● Replace the oil seals every two years. ● Replace the brake hoses every four years. Recommended brake fluid: DOT 4 ● ● Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. Have a Yamaha dealer check the cause if the brake fluid level goes down. Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance. Be careful that water does not enter the master cylinder reservoirs when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. 8-42 EE.book Page 43 Friday, May 6, 2005 8:59 AM EBU11870 Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer check the brake system. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. ● 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. a. Front brake lever free play 8-43 EE.book Page 44 Friday, May 6, 2005 8:59 AM EBU09631 Adjusting the rear brake lever and brake pedal Adjusting the rear brake lever The rear brake lever free play should be 0.5– 2.0 mm (0.02–0.08 in). 1. Loosen the locknut. If correct free play cannot be obtained, ask a Yamaha dealer to make that adjustment. NOTE: When adjusting the rear brake lever free play: ● Be sure not to step on the brake pedal. ● Make sure the brake pedal does not move. _ _ 1. Locknut 2. Adjusting bolt c. Rear brake lever free play 2. Turn the adjusting bolt in direction a to increase free play, and in direction b to decrease free play. 3. Tighten the locknut. 8-44 EE.book Page 45 Friday, May 6, 2005 8:59 AM Adjusting the brake pedal The top of the brake pedal should be positioned 72 mm (2.83 in) above the top of the footrest. If not, ask a Yamaha dealer to adjust it. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. ● 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. a. Brake pedal position 8-45 EE.book Page 46 Friday, May 6, 2005 8:59 AM EBU12590 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and rear brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Remove panel B. (See page 8-9 for panel removal and installation procedures.) 2. Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction a. To make the brake light come on later, turn the adjusting nut in direction b. 3. Install the panel. 1. Rear brake light switch 8-46 2. Adjusting nut EE.book Page 47 Friday, May 6, 2005 8:59 AM EBU00356 EBU12600 Cable inspection and lubrication Lubricating the brake levers and brake pedal Lubricate the pivoting parts. WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables. NOTE: To access the brake pedal pivot, remove panel B. (See page 8-9 for panel removal and installation procedures.) _ _ Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-47 EE.book Page 48 Friday, May 6, 2005 8:59 AM EBU13110 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun. 1. Upper knuckle 2. Lower knuckle Recommended lubricant: Lithium-soap-based grease 8-48 EE.book Page 49 Friday, May 6, 2005 8:59 AM EBU01112 EBU11211 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Wheel installation 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 nut with its tapered side towards the wheel. _ _ 1. Nut (× 4) 1. Arrow mark 8-49 EE.book Page 50 Friday, May 6, 2005 8:59 AM EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. 1. Tapered nut 2. Lower the ATV so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf) 1. Negative battery terminal 8-50 2. Positive battery terminal EE.book Page 51 Friday, May 6, 2005 8:59 AM CAUTION: HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention. EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space. Do not try to remove the sealing caps of the battery cells. You may damage the battery. WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases. 8-51 EE.book Page 52 Friday, May 6, 2005 8:59 AM EBU00385 EBU08762* Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. Fuse replacement 1. The main fuse and the fuse box are located under the seat. 2. If a fuse is blown, turn off the main switch and the switch of the circuit in question. Then, install a new fuse of the specified amperage. Turn on the main switch. If the fuse immediately blows again, consult a Yamaha dealer. CAUTION: A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type battery. Using a conventional battery charger may shorten the battery life. 2. Always make sure the connections are correct when putting the battery back in the machine. 8-52 EE.book Page 53 Friday, May 6, 2005 8:59 AM 1. Main fuse 1. Main fuse 2. Fuse box 1. 3. 5. 6. 7. Headlight fuse 2. Ignition fuse Auxiliary DC jack fuse 4. Four-wheel drive fuse Signaling system fuse Backup fuse (for odometer and clock) Spare fuse (× 3) Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Four-wheel drive fuse: Signaling system fuse: Backup fuse: 2. Spare main fuse 8-53 30.0 A 15.0 A 10.0 A 10.0 A 3.0 A 10.0 A 10.0 A EE.book Page 54 Friday, May 6, 2005 8:59 AM EBU15951 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the bulb holder cover at the rear of the headlight by pulling it off. WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse. CAUTION: _ To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 1. Headlight bulb holder cover _ 8-54 EE.book Page 55 Friday, May 6, 2005 8:59 AM 2. Disconnect the headlight coupler by lifting the tab as shown and pulling out the coupler. 3. Remove the headlight bulb holder assembly by turning it counterclockwise. 1. Headlight bulb holder assembly 1. Headlight coupler NOTE: The headlight bulb cannot be removed from the headlight bulb holder. To replace the headlight bulb, replace the headlight bulb holder assembly. _ _ 8-55 EE.book Page 56 Friday, May 6, 2005 8:59 AM WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. 1. Do not touch the glass part of the bulb. CAUTION: _ Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. 4. Install a new headlight bulb holder assembly by inserting it and turning it clockwise. _ 8-56 EE.book Page 57 Friday, May 6, 2005 8:59 AM EBU01089 Headlight beam adjustment 5. Connect the headlight coupler. 6. Install the headlight bulb holder cover at the rear of the headlight. CAUTION: _ It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. 1. Headlight beam adjusting screw 8-57 EE.book Page 58 Friday, May 6, 2005 8:59 AM EBU09640 Tail/brake light bulb replacement 1. Remove the nuts together with the washers. 1. Tail/brake light unit 1. Tail/brake light unit 2. Tail/brake light bulb holder 3. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 2. Nut (× 2) 2. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 8-58 EE.book Page 59 Friday, May 6, 2005 8:59 AM EBU00412 1. Tail/brake light bulb holder Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer. The skilled technicians at a Yamaha dealership have the tools, experience, and knowhow to properly service your machine. Use only genuine Yamaha parts on your machine. Imitation parts may look like Yamaha parts, but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills. 2. Bulb 4. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the washers, and then install the nuts. 8-59 EE.book Page 60 Friday, May 6, 2005 8:59 AM WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces. 8-60 EE.book Page 61 Friday, May 6, 2005 8:59 AM EBU08061 Troubleshooting charts Starting problems or poor engine performance Turn the fuel cock lever to “ON”. There is fuel. Turn the fuel cock lever to “OFF”. Remove the fuel hose from the fuel cock. Some fuel. Turn the fuel cock lever to “RES”. Restart the engine. No fuel. Supply fuel. 1. Fuel Check if there is fuel in the fuel tank. 2. Compression Use the electric starter to see if there is compression. 3. Ignition There is compression. Compression normal. No compression. Ask a Yamaha dealer to inspect. Wet Dry Wipe clean with dry cloth. Attach spark plug cap and ground to chassis. Use the electric starter. Battery is good. Engine turns over slowly. Check the battery lead connections, and charge the battery if necessary. Ignition system is normal. Adjust the spark plug gap or replace the spark plug. Use the electric starter. 8-61 Fuel cock is clogged. Spark is weak. No spark. Engine turns over quickly. No fuel. Clean the fuel cock. Spark is good. Remove the spark plug and check the electrodes. 4. Battery Check the fuel flow. Ask a Yamaha dealer to inspect. EE.book Page 62 Friday, May 6, 2005 8:59 AM Engine overheating HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. 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. Leakage. Ask a Yamaha dealer to inspect and repair the cooling system. No leakage. Add coolant. (See NOTE.) Level is low, check the cooling system for leakage. Wait until the engine has cooled. Check the coolant level in the coolant reservoir and/or radiator. Level is OK. Restart the engine. If the engine overheats again, ask a Yamaha dealer to inspect and/or repair the cooling system. NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible. _ _ 8-62 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00419 CLEANING AND STORAGE CAUTION: 1- Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. b. Make sure the spark plug and all filler caps are properly installed. 2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply degreaser to the wheel axles. 3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job. 4. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-get-at places. 5. Rinse the machine off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbent cloth. 9-1 EE.book Page 2 Friday, May 6, 2005 8:59 AM 6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. WARNING POTENTIAL HAZARD Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping ability, increasing the chance of an accident. HOW TO AVOID THE HAZARD Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 9-2 EE.book Page 3 Friday, May 6, 2005 8:59 AM EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product. 2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug. Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil. 3. Lubricate all control cables. 4. Block up the frame to raise all wheels off the ground. 5. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. 6. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover. Specified amount: 1 oz of stabilizer to each gallon of fuel (or 7.5 cc of stabilizer to each liter of fuel) NOTE: Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system. Consult a Yamaha dealer if the fuel system needs to be drained instead. 9-3 EE.book Page 4 Friday, May 6, 2005 8:59 AM 7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine. 9-4 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00428 SPECIFICATIONS 1- Model YFM45FAV Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system 1,993 mm (78.5 in) 1,093 mm (43.0 in) 1,120 mm (44.1 in) 830 mm (32.7 in) 1,233 mm (48.5 in) 245 mm (9.65 in) 3,000 mm (118.1 in) 285.0 kg (628 lb) Liquid-cooled 4-stroke, SOHC Forward-inclined single cylinder 421.0 cm3 84.5 × 75.0 mm (3.33 × 2.95 in) 10.00 : 1 Electric and recoil starter Wet sump 10-1 EE.book Page 2 Friday, May 6, 2005 8:59 AM Model YFM45FAV 1 Engine oil: Type 2 0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F 3 4 YAMALUBE 4 (20W40) or SAE 20W40 5 YAMALUBE 4 (10W30) or SAE 10W30 6 SAE 5W30 -20˚ Recommended engine oil classification -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Quantity: Without oil filter cartridge replacement With oil filter cartridge replacement 7 8 9 10 11 12 13 14 2.30 L (2.02 Imp qt, 2.43 US qt) 2.40 L (2.11 Imp qt, 2.54 US qt) 10-2 EE.book Page 3 Friday, May 6, 2005 8:59 AM Model YFM45FAV Final gear case oil: Type Quantity Differential gear case oil: Type Quantity Radiator capacity (including all routes): Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type/quantity Manufacturer SAE 80 API GL-4 Hypoid gear oil 0.16 L (0.14 Imp qt, 0.17 US qt) SAE 80 API GL-4 Hypoid gear oil 0.23 L (0.20 Imp qt, 0.24 US qt) 1.30 L (1.14 Imp qt, 1.37 US qt) Wet type element UNLEADED GASOLINE ONLY 15.0 L (3.30 lmp gal, 3.96 US gal) 4.5 L (0.99 lmp gal, 1.19 US gal) BSR33 / 1 MIKUNI 10-3 EE.book Page 4 Friday, May 6, 2005 8:59 AM Model Spark plug: Type/manufacturer Spark plug gap Clutch type: Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio Chassis: Frame type Caster angle Trail Tire: Type Size YFM45FAV DR8EA / NGK 0.6–0.7 mm (0.024–0.028 in) Wet, centrifugal automatic V-belt Shaft drive 39/24 × 24/18 × 33/9 (7.944) V-belt automatic Left hand operation 29/17 (1.706) 45/16 (2.813) 38/23 (1.652) low high Steel tube frame 2.5° 8.5 mm (0.33 in) Tubeless AT25 × 8 - 12 AT25 × 10 - 12 front rear 10-4 EE.book Page 5 Friday, May 6, 2005 8:59 AM Model Brake: Front brake Rear brake YFM45FAV type operation type operation Dual disc brake Right hand operation Single disc brake Left hand and right foot operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Headlight type: Double wishbone Double wishbone Coil spring / oil damper Coil spring / oil damper 160.0 mm (6.30 in) 180.0 mm (7.09 in) DC. C.D.I. A.C. magneto YTX20L-BS 12 V 18.0 Ah Krypton bulb 10-5 EE.book Page 6 Friday, May 6, 2005 8:59 AM Model YFM45FAV Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator light: Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light High-range indicator light Low-range indicator light Differential gear lock indicator light Fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel drive fuse Signaling system fuse Backup fuse 12 V 30W/30.0 W × 2 12 V 5W/21.0 W × 1 LED LED LED LED LED LED LED 30.0 A 15.0 A 10.0 A 10.0 A 3.0 A 10.0 A 10.0 A 10-6 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00430 1- 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 design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. “AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW.” These acts include tampering with the following systems; i.e., modification, removal, etc. Exhaust system Muffler Exhaust pipe Silencer Intake system Air cleaner case Air cleaner element Intake duct 11-1 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU15740 1- MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work. ACL-07E 1 2 3 4 5 MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 6 month km (mi) hours 1 320 (200) 20 7 8 3 1,300 (800) 80 6 2,500 (1,600) 160 12 5,000 (3,200) 320 9 18 7,500 (4,800) 480 10 24 10,000 (6,400) 640 30 12,500 (8,000) 800 36 15,000 (9,600) 960 42 17,500 (11,200) 1,120 48 20,000 (12,800) 1,280 54 22,500 (14,400) 1,440 60 25,000 (16,000) 1,600 11 12 13 14 12-1 E-13.fm Page 1 Monday, August 8, 2005 4:27 PM EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1 EE.book Page 2 Friday, May 6, 2005 8:59 AM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 13-2 EE.book Page 1 Friday, May 6, 2005 8:59 AM EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1 EE.book Page 2 Friday, May 6, 2005 8:59 AM 1 2 3 4 5 6 7 8 9 10 11 12 13 EBU00436 14 WARNING _ Indicates a potential hazard that could result in serious injury or death. 14-2 EE.book Page 3 Friday, May 6, 2005 8:59 AM EBU00437 EBU00438 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns. on public roads-a collision can occur with avoid paved surfaces-pavement may another vehicle. seriously affect handling and control. with a passenger-passengers affect balance and steering and increase risk of losing control. LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN USA 2005.09-4.0×1 CR (E)