Get notified when we add a new AroSpartana Manual

We cover 60 Aro vehicles, were you looking for one of these?

Skoda - Auto - skoda-karoq-2017-110444
Skoda - Auto - skoda-karoq-2017-brukerhandbok-110449
Skoda - Auto - skoda-karoq-2017-110460
Skoda - Auto - skoda-karoq-2017-omistajan-kasikirja-110439
Cars & Automotive Accessories - Kenwood - C929
Skoda - Auto - skoda-karoq-2017-savininko-vadovas-110446
Skoda - Auto - skoda-karoq-2017-110457
Skoda - Auto - skoda-karoq-2017-ipasnieka-rokasgramata-110447
Skoda - Auto - skoda-karoq-2017-manual-del-propietario-110438
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-2017-110431
Pool Equipment - Haywood-Pool - Super Pump~All Super Pump Models
Skoda - Auto - skoda-karoq-2017-prirocnik-za-lastnika-110456
VCRs & Accessories - Hitachi Electronics - VTM171A
Skoda - Auto - skoda-karoq-2017-110453
Skoda - Auto - skoda-karoq-2017-handleiding-110448
Skoda - Auto - skoda-karoq-2017-instrukcja-obslugi-110450
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
Barossa - Motorcycle - Barossa__Barossa_PYTHON_100cc_parts
Skoda - Auto - skoda-karoq-2017-manual-do-proprietario-110451
Furniture & Storage - Blue Rhino - GAD1375SP
Skoda - Auto - skoda-karoq-2017-uzivatelska-prirucka-110455
Skoda - Auto - skoda-karoq-2017-kezelesi-utmutato-110443
Sewing Machine - Singer - 14T968DC %7C PROFESSIONAL 5
1981-1995--Chrysler--Lebaron--4 Cylinders B 2.2L 2BL SOHC--31218101
Skoda - Auto - skoda-karoq-2017-110432
Skoda - Auto - skoda-karoq-2017-110441
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.6L 2BL SOHC--31218102
Video Cameras, Camcorders, & Accessories - Canon - ZR900 Camcorder
Grills & Accessories - Blue Rhino - Blue Rhino WAD996SP
Skoda - Auto - skoda-karoq-2017-agarmanual-110454
Skoda - Auto - skoda-karoq-2017-manuel-du-proprietaire-110440
Cars & Automotive Accessories - Kenwood - DPX-510
Skoda - Auto - skoda-karoq-2017-manuale-del-proprietario-110445
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.2L TBI SOHC--31034802
Skoda - Auto - skoda-karoq-2017-omaniku-kasiraamat-110436
Skoda - Auto - skoda-karoq-2017-110459
Skoda - Auto - skoda-karoq-2017-instruktionsbog-110435
Printers & Accessories - Xerox - WorkCentre Pro C2128~C2636~C3545
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.2L TBI SOHC--31095601
Skoda - Auto - skoda-karoq-2017-manualul-de-utilizare-110452
Skoda - Auto - skoda-karoq-2017-owner-s-manual-110437
Cameras & Accessories - Nikon - Nikon COOLPIX S203
1981-1995--Chrysler--Lebaron--4 Cylinders J 2.5L MFI Turbo SOHC--31006702
Cars & Automotive Accessories - Ford - F-150 2001
Speaker Systems - JBL - Xtreme
Ducati - Motorcycle - Ducati_M620_ie_Parts_2002
Sewing Machine - Brother - Brother BAS-511
Speakers & Audio Accessories - Dual - Dual - SX652 ~ SX692
Skoda - Auto - skoda-karoq-2017-vodic-za-korisnike-110442
Sewing Machine - Brother - Brother DB2-B798
Power Tools & Accessories - STIHL - STIHL Trimmer FS 40, FS 50
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 YFZ450XZ YFZ450XBBZ WARNING LIT-11626-23-47 This ATV should not be ridden by anyone under 16 years of age. 46D-28199-10 DIC183 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU17170 INTRODUCTION EBU17302 Congratulations on your purchase of the Yamaha YFZ450XZ/YFZ450XBBZ. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting 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 the 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 notice 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 should not be ridden by anyone under 16 years of age. ● This ATV is a high-performance ATV for off-road use only, for sport-type recreational and competitive use by experienced operators. U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 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: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. TIP A TIP provides key information to make procedures easier or clearer. * Product and specifications are subject to change without notice. U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU17350 IMPORTANT NOTICE EBU17362 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. EBU17382 YFZ450XZ/YFZ450XBBZ OWNER’S MANUAL ©2009 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan. P/N LIT-11626-23-47 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 1-1 SAFETY INFORMATION .............................. 2-1 DESCRIPTION .............................................. 3-1 Left view ...................................................... 3-1 Right view.................................................... 3-1 Controls and instruments ............................ 3-2 INSTRUMENT AND CONTROL FUNCTIONS .................................................. 4-1 Main switch ................................................ 4-1 Indicator light and warning lights ................ 4-2 Handlebar switches .................................... 4-3 Throttle lever .............................................. 4-4 Speed limiter .............................................. 4-5 Clutch lever .................................................4-5 Brake lever ..................................................4-6 Brake pedal .................................................4-6 Parking brake lever .....................................4-7 Shift pedal ...................................................4-8 Fuel tank cap ..............................................4-8 Fuel .............................................................4-9 Seat ..........................................................4-11 Adjusting the front shock absorber assemblies ..............................................4-11 Adjusting the rear shock absorber assembly .................................................4-17 Handlebar position ....................................4-25 PRE-OPERATION CHECKS ..........................5-1 Fuel .............................................................5-3 Engine oil ....................................................5-3 Coolant .......................................................5-3 Front and rear brakes .................................5-3 Throttle lever ...............................................5-4 Drive chain ..................................................5-4 Tires ............................................................5-4 Chassis fasteners .......................................5-6 Instruments, lights and switches .................5-6 OPERATION...................................................6-1 Starting the engine ......................................6-1 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM Shifting ....................................................... 6-2 Engine break-in .......................................... 6-4 Parking ....................................................... 6-4 Parking on a slope ..................................... 6-5 Accessories and loading ............................ 6-6 RIDING YOUR ATV ...................................... 7-1 GETTING TO KNOW YOUR ATV............... 7-2 RIDE WITH CARE AND GOOD JUDGMENT .............................................. 7-2 BE CAREFUL WHERE YOU RIDE............. 7-9 TURNING YOUR ATV .............................. 7-12 CLIMBING UPHILL ................................... 7-13 RIDING DOWNHILL.................................. 7-17 CROSSING A SLOPE............................... 7-18 CROSSING THROUGH SHALLOW WATER ................................................... 7-19 RIDING OVER ROUGH TERRAIN ........... 7-20 SLIDING AND SKIDDING......................... 7-21 WHAT TO DO IF... .................................... 7-22 WHAT TO DO... ........................................ 7-22 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 ..........................................................8-5 Removing and installing panels ..................8-9 Checking the spark plug ...........................8-13 Engine oil and oil filter element .................8-14 Coolant .....................................................8-20 Cleaning the air filter element ...................8-21 Cleaning the spark arrester ......................8-25 Adjusting the throttle cable free play .........8-27 Valve clearance ........................................8-28 Brakes .......................................................8-28 Checking the front and rear brake pads ...8-28 Checking the brake fluid level ...................8-29 Changing the brake fluid ...........................8-30 Checking the front brake lever free play ...8-31 Checking the brake pedal position ............8-31 Adjusting the parking brake free play .......8-31 Brake light switches ..................................8-33 Adjusting the clutch lever free play ...........8-33 Drive chain slack .......................................8-34 Lubricating the drive chain ........................8-36 Checking and lubricating the cables .........8-37 Checking and lubricating the brake and clutch levers ............................................8-38 Checking the shift pedal ...........................8-39 Checking and lubricating the brake pedal .......................................................8-39 U46D10E0.book Page 3 Thursday, June 11, 2009 12:59 PM Checking the wheel hub bearings ............ 8-39 Lubricating the swingarm pivots ............... 8-40 Lubricating the upper and lower arm pivots ...................................................... 8-40 Lubricating the steering shaft ................... 8-41 Battery ...................................................... 8-42 Replacing the fuse ................................... 8-45 Replacing a headlight bulb ....................... 8-45 Adjusting a headlight beam ...................... 8-47 Tail/brake light .......................................... 8-47 Removing a wheel .................................... 8-47 Installing a wheel ...................................... 8-48 Troubleshooting ....................................... 8-49 Troubleshooting charts ............................. 8-51 CLEANING AND STORAGE.......................... 9-1 Cleaning ..................................................... 9-1 Storage ....................................................... 9-2 SPECIFICATIONS ...................................... 10-1 CONSUMER INFORMATION ...................... 11-1 Identification numbers .............................. 11-1 Noise regulation ....................................... 11-4 Maintenance record ................................. 11-5 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY ........ 11-6 YAMAHA EXTENDED SERVICE (Y.E.S.) ...................................................11-8 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 1 6 2 7 3 7 4 5 1-1 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM EBU17670 1 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer. 1-2 U46D10E0.book Page 3 Thursday, June 11, 2009 12:59 PM 1 2 1 3 Certification of Compliance This ATV complies with applicable provisions of ANSI/SVIA 1-2007 and is subject to an approved ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product Safety Commission. YAMAHA MOTOR CORPORATION U.S.A. 6555 Katella Avenue, Cypress, California 90630-5101, U.S.A. 43P-2817J-00 1-3 U46D10E0.book Page 4 Thursday, June 11, 2009 12:59 PM 4 1 6 WARNING PREMIUM UNLEADED GASOLINE ONLY 91 Min. Pump Octane (R+M) / 2 NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 5PW-2415E-11 7 WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. Do not incinerate, puncture or open. 5FE-2151H-01 4AA-22259-80 5 WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. OPERATING TIRE PRESSURE : Set with tires cold Recommended : Front : 4.0 psi (27.5 kPa) Rear : 4.4 psi (30.0 kPa) : Front : 3.6 psi (24.5 kPa) Minimum Rear : 4.0 psi (27.0 kPa) Never set tire pressure below minimum. It could cause the tire to dislodge from the rim. LOADING Maximum weight capacity : 220 lbs. (100 kg) Includes weight of operator, cargo and accessories. 5D3-2816M-U0 1-4 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU17431 SAFETY INFORMATION ● EBU29352 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 1800-887-2887 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 90 cc. ● ● ● ● ● ● ● 2-1 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. 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 a 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 riding 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. 2 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM ● 2 ● ● ● ● ● ● 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 footrests 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 and never turn at excessive speeds. 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 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 U46D10E0.book Page 3 Thursday, June 11, 2009 12:59 PM ● ● ● ● ● 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. 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. ● ● ● 2-3 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. 2 U46D10E0.book Page 4 Thursday, June 11, 2009 12:59 PM ● EWB00071 2 WARNING Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death. Carbon Monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust. Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas. If you experience any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT. ● Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels. ● Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports. Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors. 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 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 12 3 5 4 1 6 2 3 4 5 3 9 8 9 8 7 7 1. Front shock absorber assembly compression damping force adjusting bolt (for fast compression damping) 2. Front shock absorber assembly compression damping force adjusting screw (for slow compression damping) 3. Front shock absorber assembly spring preload adjusting nut 4. Engine oil tank filler cap 5. Rear brake fluid reservoir 6. Battery 7. Shift pedal 8. Coolant reservoir 9. Front shock absorber assembly rebound damping force adjusting screw 6 1. Spark arrester 2. Fuse 3. Rear shock absorber assembly spring preload adjusting nut 4. Rear shock absorber assembly compression damping force adjusting bolt (for fast compression damping) 5. Rear shock absorber assembly compression damping force adjusting screw (for slow compression damping) 6. Oil filter element 7. Brake pedal 8. Rear brake light switch 9. Rear shock absorber assembly rebound damping force adjusting screw 3-1 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM EBU17712 Controls and instruments 1 2 3 4 5 6 7 3 1. 2. 3. 4. 5. 6. 7. Clutch lever Parking brake lever Left handlebar switches Fuel tank cap Main switch Throttle lever Brake lever TIP The ATV you have purchased may differ slightly from the figures shown in this manual. 3-2 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU17725 INSTRUMENT AND CONTROL FUNCTIONS EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. OFF ON 1 EBU17760 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. 1. Main switch OFF All electrical systems are off. The key can be removed. 4-1 4 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM EBU29381 EBU26702 Indicator light and warning lights Coolant temperature warning light “ ” This warning light comes on when the engine overheats. When this occurs during operation, stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes. The electrical circuit of the warning light can be checked by turning the key to “ON”. The warning light should come on for a few seconds, and then go off. If the warning light does not come on initially when the key is turned to “ON”, or if the warning light remains on, have a Yamaha dealer check the electrical circuit. 1 2 3 4 4 1. 2. 3. 4. Fuel level warning light “ ” Engine trouble warning light “ ” Coolant temperature warning light “ Neutral indicator light “N” ECB00010 NOTICE ● The engine may overheat if the ATV is overloaded. In this case, reduce the load to specification. ● Start the engine after making sure that the warning light is out. Continuous use while the warning light is on may cause damage to the engine. ” EBU17860 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. 4-2 U46D10E0.book Page 3 Thursday, June 11, 2009 12:59 PM If the warning light does not come on initially when the key is turned to “ON”, or if the warning light remains on, have a Yamaha dealer check the electrical circuit. EBU29391 Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 3.4 L (0.90 US gal, 0.75 Imp.gal). When this occurs, refuel as soon as possible. The electrical circuit of the warning light can be checked by setting the engine stop switch to “ ” and turning the key to “ON”. The warning light should come on for a few seconds, and then go off. If the warning light does not come on initially when the key is turned to “ON”, or if the warning light remains on, have a Yamaha dealer check the electrical circuit. EBU18061 Handlebar switches 4 1 2 3 EBU26723 Engine trouble warning light “ ” This warning light comes on or flashes when an electrical circuit monitoring the engine is not working correctly. When this occurs, have a Yamaha dealer check the self-diagnosis system. The electrical circuit of the warning light can be checked by turning the key to “ON”. The warning light should come on for a few seconds, and then go off. 1. Light switch “ / 2. Engine stop switch “ 3. Start switch “ ” /OFF” / ” EBU18080 Engine stop switch “ / ” Set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch 4-3 U46D10E0.book Page 4 Thursday, June 11, 2009 12:59 PM to stop the engine in an emergency situation. The engine will not start or run when this switch is set to “ ”. EBU18282 Throttle lever Once the engine is running, pushing the throttle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position. Because the throttle is springloaded, the ATV will decelerate, and the engine will return to an idle any time the throttle lever is released. EBU18101 4 Start switch “ ” Push this switch to crank the engine with the starter. See the starting instructions on page 6-1 prior to starting the engine. EBU18152 Light switch “ / /OFF” Set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to turn on the high beams and the taillight. Set the switch to “OFF” to turn off all the lights. ECB00041 NOTICE Do not use the headlights with the engine turned off for an extended period of time, otherwise 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. See page 8-42 for battery charging information. 1 1. Throttle lever 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. 4-4 U46D10E0.book Page 5 Thursday, June 11, 2009 12:59 PM EBU18323 3 Speed limiter Your ATV is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (a). To decrease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b). Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be damaged. Always make sure the throttle lever free play is adjusted to 2.0–4.0 mm (0.08–0.16 in). (See page 8-27.) WARNING! Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, resulting in an accident. [EWB00241] 1 2 (b) (a) 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in) 3. Tighten the locknut. EBU18382 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporated in the clutch lever holder. To disengage the clutch, pull the clutch lever toward the handlebar grip. To engage the clutch, release the clutch lever. The clutch lever should be pulled rapidly and re- 4-5 4 U46D10E0.book Page 6 Thursday, June 11, 2009 12:59 PM leased slowly for smooth clutch operation. (See page 6-1 for a description of the ignition circuit cutoff system.) 2 3 1 4 4 1. 2. 3. 4. 1. Clutch lever Brake lever Locknut Brake lever position adjusting bolt Distance between brake lever and handlebar grip EBU18432 EBU18421 Brake pedal Brake lever The brake pedal is located on the right side of the ATV. To apply the rear brake, push down on the brake pedal. The brake lever is located on the right handlebar. To apply the front brake, pull the brake lever toward the handlebar grip. The brake lever is equipped with a position adjusting bolt. To adjust the distance between the brake lever and the handlebar grip, hold the brake lever away from the handlebar so it does not contact the adjusting bolt, loosen the locknut, turn the adjusting bolt, and then tighten the locknut. 4-6 U46D10E0.book Page 7 Thursday, June 11, 2009 12:59 PM 1 4 1. Parking brake lever (locked position) 1. Brake pedal EBU18520 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a). To release the parking brake, move the parking brake lever in direction (b). 1. Parking brake lever (unlocked position) 4-7 U46D10E0.book Page 8 Thursday, June 11, 2009 12:59 PM EWB00220 ● 4 ● WARNING Always set the parking brake before starting the engine. The ATV could start moving unexpectedly if the parking brake is not applied. This could cause loss of control or a collision. Always be sure you have released the parking brake before you begin to ride. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely. 1 1. Shift pedal EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. EBU18530 Shift pedal This ATV is equipped with a constant-mesh 5speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. 4-8 U46D10E0.book Page 9 Thursday, June 11, 2009 12:59 PM of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole. Stop filling when the fuel reaches the bottom of the filler tube. Because fuel expands when it heats up, heat from the engine or the sun can cause fuel to spill out of the fuel tank. 1 1. Fuel tank cap 1 EBU18801 Fuel Make sure there is sufficient gasoline in the tank. EWB02521 WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1. Maximum fuel level 2. Fuel tank filler tube 1. Before refueling, turn off the engine and be sure that no one is sitting on the vehicle. Never refuel while smoking, or while in the vicinity 4-9 2 4 U46D10E0.book Page 10 Thursday, June 11, 2009 12:59 PM ECB00070 Recommended fuel: PREMIUM UNLEADED GASOLINE ONLY Fuel tank capacity: 10.0 L (2.64 US gal, 2.20 Imp.gal) Fuel reserve amount: 3.4 L (0.90 US gal, 0.75 Imp.gal) 4 NOTICE 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. Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number [(R+M)/2] of 91 or higher, or a research octane number of 97 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. 3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. [ECB00981] 4. Turn the fuel tank cap fully clockwise to make sure it is securely closed. EWB02531 Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10% (E10). Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems. WARNING Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. 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. 4-10 U46D10E0.book Page 11 Thursday, June 11, 2009 12:59 PM EBU18891 1 Seat To remove the seat Insert your hand between the rear of the seat and the rear fender, pull the seat lock lever upward and pull up the seat at the rear. 4 1 2 1. Projection 2. Seat holder EBU29304 Adjusting the front shock absorber assemblies These shock absorber assemblies are equipped with a spring preload adjusting nut, a rebound damping force adjusting screw, with a compression damping force adjusting bolt (for fast compression damping), and a compression damping force adjusting screw (for slow compression damping). 1. Seat lock lever 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. Make sure that the seat is securely fitted. 4-11 U46D10E0.book Page 12 Thursday, June 11, 2009 12:59 PM number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. EWB02491 ● 4 ● WARNING Suspension components become hot during operation. Never touch the compression damping force adjusting bolt and screw, the rebound damping force adjusting screw or the oil reservoir with your bare hand or skin until suspension components have cooled. Always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. Spring preload 1. Loosen the locknut. 2. Turn the spring preload adjusting nut in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. ECB00090 NOTICE Never turn an adjusting mechanism beyond the minimum and maximum settings. 1 (a) 2 TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the (b) 1. Locknut 2. Spring preload adjusting nut 3. Special wrench 4-12 3 U46D10E0.book Page 13 Thursday, June 11, 2009 12:59 PM TIP ● A special wrench can be obtained at a Yamaha dealer to make this adjustment. ● The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the higher the spring preload; the longer distance A is, the lower the spring preload. With each complete turn of the adjusting nut, distance A is changed by 1.5 mm (0.06 in). 1 1. Distance A Spring preload setting: Minimum (soft): Distance A = 263.8 mm (10.39 in) Standard: Distance A = 253.8 mm (9.99 in) Maximum (hard): Distance A = 243.8 mm (9.60 in) 3. Tighten the locknut to the specified torque. NOTICE: Always tighten the locknut against the adjusting nut, and then tighten it to the specified torque. [ECB00081] Tightening torque: Locknut: 50 Nm (5.0 m·kgf, 36 ft·lbf) 4-13 4 U46D10E0.book Page 14 Thursday, June 11, 2009 12:59 PM Rebound damping force Turn the rebound damping force adjusting screw in direction (a) to increase the rebound damping force and thereby harden the damping, and in direction (b) to decrease the rebound damping force and thereby soften the damping. Rebound damping setting: Minimum (soft): 20 click(s) in direction (b)* Standard: 12 click(s) in direction (b)* Maximum (hard): 1 click(s) in direction (b)* * With the adjusting screw fully turned in direction (a) 4 TIP Make sure that the position indicator mark is aligned with the match mark when the shock absorber assembly is set to the standard setting. (a) (b) 1 2 3 Compression damping force 1. Rebound damping force adjusting screw 2. Position indicator mark 3. Match mark Compression damping force (for fast compression damping) To increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting bolt in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting bolt in direction (b). 4-14 U46D10E0.book Page 15 Thursday, June 11, 2009 12:59 PM (b) 1 TIP Make sure that the position indicator mark is aligned with the match mark when the shock absorber assembly is set to the standard setting. (a) 1 Compression damping force (for slow compression damping) To increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b). 2 3 1. Compression damping force adjusting bolt (for fast compression damping) 2. Position indicator mark (for fast compression damping) 3. Match mark Compression damping setting (for fast compression damping): Minimum (soft): 2 turn(s) out from the fully turned in position Standard: 1 turn(s) out from the fully turned in position Maximum (hard): Adjusting bolt fully turned in 4-15 4 U46D10E0.book Page 16 Thursday, June 11, 2009 12:59 PM (b) 1 TIP Make sure that the position indicator mark is aligned with the match mark when the shock absorber assembly is set to the standard setting. (a) EWB00410 1 WARNING These shock absorber assemblies contain highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber assemblies. ● Do not tamper with or attempt to open the cylinder assemblies. ● Do not subject the shock absorber assemblies to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure. ● Do not deform or damage the cylinders in any way. Cylinder damage will result in poor damping performance. ● Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha dealer for any service. 2 4 3 1. Compression damping force adjusting screw (for slow compression damping) 2. Position indicator mark (for slow compression damping) 3. Match mark Compression damping setting (for slow compression damping): Minimum (soft): 18 click(s) in direction (b)* Standard: 10 click(s) in direction (b)* Maximum (hard): 1 click(s) in direction (b)* * With the adjusting screw fully turned in direction (a) 4-16 U46D10E0.book Page 17 Thursday, June 11, 2009 12:59 PM EBU29525 TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. Adjusting the rear shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting nut, a rebound damping force adjusting screw, a compression damping force adjusting bolt (for fast compression damping), and a compression damping force adjusting screw (for slow compression damping). EWB02680 WARNING Suspension components become hot during operation. Never touch the compression damping force adjusting bolt and screw, the rebound damping force adjusting screw or the oil reservoir with your bare hand or skin until the suspension components have cooled. Spring preload 1. Remove panel C. (See page 8-9.) 2. Remove the clip from the hose holder, remove the bolt, and then move the blow-by gas chamber away from the vehicle. ECB00090 NOTICE Never turn an adjusting mechanism beyond the minimum and maximum settings. 4-17 4 U46D10E0.book Page 18 Thursday, June 11, 2009 12:59 PM 3 1 2 4 1 4 1. 2. 3. 4. 1. Clamp screw Hose holder Clip Bolt Blow-by gas chamber 4. Remove the air filter case holding plate by removing the bolts and collars. 3. Loosen the clamp screw at the air filter case side. 4-18 U46D10E0.book Page 19 Thursday, June 11, 2009 12:59 PM 1 2 3 2 4 2 1 1 1. Air filter case 2. Bolt 1. Bolt 2. Collar 3. Air filter case holding plate 6. Disconnect the coupler. 5. Remove the bolts, and then remove the air filter case by disconnecting it from the air intake duct. 1 1. Coupler 4-19 U46D10E0.book Page 20 Thursday, June 11, 2009 12:59 PM 7. Loosen the clamp screw at the throttle body side, and then disconnect the air intake duct from the throttle body. 1 (a) 1 2 2 4 (b) 3 1. Locknut 2. Spring preload adjusting nut 3. Special wrench 1. Clamp screw 2. Air intake duct TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment. ● The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the higher the spring preload; the longer distance A is, the lower the spring preload. With each complete turn of the adjusting nut, distance A is changed by 1.5 mm (0.06 in). ● 8. Loosen the locknut. 9. Turn the spring preload adjusting nut in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. 4-20 U46D10E0.book Page 21 Thursday, June 11, 2009 12:59 PM Tightening torque: Locknut: 30 Nm (3.0 m·kgf, 22 ft·lbf) Spring preload setting: Minimum (soft): Distance A = 273.5 mm (10.77 in) Standard: Distance A = 265.0 mm (10.43 in) Maximum (hard): Distance A = 253.5 mm (9.98 in) 11. Connect the air intake duct to the throttle body, and then tighten the clamp screw at the throttle body side. NOTICE: Make sure that the air intake duct is properly connected to the throttle body, and that the clamp screw is tightened securely. [ECB00961] 12. Connect the coupler. 13. Place the air filter case in the original position, connect the air intake duct to the air filter case, and then tighten the clamp screw at the air filter case side. NOTICE: Make sure that the air intake duct is properly connected to the air filter case, and that the clamp screw is tightened securely. [ECB00971] 14. Install the air filter case bolts, and then tighten them to the specified torque. 1 1. Distance A 10. Tighten the locknut to the specified torque. NOTICE: Always tighten the locknut against the adjusting nut, and then tighten it to the specified torque. [ECB00081] Tightening torque: Air filter case bolt: 6.5 Nm (0.65 m·kgf, 4.7 ft·lbf) 4-21 4 U46D10E0.book Page 22 Thursday, June 11, 2009 12:59 PM 15. Install the air filter case holding plate by installing the bolts and collars, and then tighten the bolts to the specified torque. 1 2 Tightening torque: Air filter case holding plate bolt: 6.5 Nm (0.65 m·kgf, 4.7 ft·lbf) 4 (b) 3 (a) 16. Install the blow-by gas chamber by installing the bolt, tighten the bolt to the specified torque, and then install the clip to the hose holder. 1. Rebound damping force adjusting screw 2. Position indicator mark 3. Match mark Tightening torque: Blow-by gas chamber bolt: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rebound damping setting: Minimum (soft): 20 click(s) in direction (b)* Standard: 11 click(s) in direction (b)* Maximum (hard): 1 click(s) in direction (b)* * With the adjusting screw fully turned in direction (a) 17. Install the panel. Rebound damping force Turn the rebound damping force adjusting screw in direction (a) to increase the rebound damping force and thereby harden the damping, and in direction (b) to decrease the rebound damping force and thereby soften the damping. 4-22 U46D10E0.book Page 23 Thursday, June 11, 2009 12:59 PM TIP Make sure that the position indicator mark is aligned with the match mark when the shock absorber assembly is set to the standard setting. 1 (b) (a) Compression damping force Remove the seat to make this adjustment. (See page 4-11.) If the adjustment is difficult, it may be necessary to remove panels A and D. (See page 8-9.) 1 2 3 1. Compression damping force adjusting bolt (for fast compression damping) 2. Position indicator mark (for fast compression damping) 3. Match mark Compression damping force (for fast compression damping) To increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting bolt in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting bolt in direction (b). Compression damping setting (for fast compression damping): Minimum (soft): 2 turn(s) out from the fully turned in position Standard: 1 turn(s) out from the fully turned in position Maximum (hard): Adjusting bolt fully turned in 4-23 4 U46D10E0.book Page 24 Thursday, June 11, 2009 12:59 PM TIP Make sure that the position indicator mark is aligned with the match mark when the shock absorber assembly is set to the standard setting. 4 (a) 1 (b) Compression damping force (for slow compression damping) To increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b). 1 2 3 1. Compression damping force adjusting screw (for slow compression damping) 2. Position indicator mark (for slow compression damping) 3. Match mark Compression damping setting (for slow compression damping): Minimum (soft): 18 click(s) in direction (b)* Standard: 8 click(s) in direction (b)* Maximum (hard): 1 click(s) in direction (b)* * With the adjusting screw fully turned in direction (a) 4-24 U46D10E0.book Page 25 Thursday, June 11, 2009 12:59 PM EBU29401 TIP Make sure that the position indicator mark is aligned with the match mark when the shock absorber assembly is set to the standard setting. Handlebar position The handlebar can be adjusted to one of four positions to suit the rider’s preference. Have a Yamaha dealer adjust the position of the handlebar. EWB00430 1 WARNING This shock absorber assembly contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber assembly. ● Do not tamper with or attempt to open the cylinder assembly. ● Do not subject the shock absorber assembly to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure. ● Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. ● Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha dealer for any service. 4 1. Handlebar EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 4-25 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU19201 PRE-OPERATION CHECKS EBU19224 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. EWB00481 5 WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points: ITEM Fuel Engine oil Coolant Front brake ROUTINE • Check fuel level in fuel tank, and add recommended fuel if necessary. • Check fuel line for leakage. Correct if necessary. • Check oil level in engine, and add recommended oil to specified level if necessary. • Check ATV for oil leakage. Correct if necessary. • Check coolant level in reservoir, and add recommended coolant to specified level if necessary. • Check cooling system for leakage. Correct if necessary. • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear, and replace if necessary. • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary. • Check hydraulic system for leakage. Correct if necessary. 5-1 PAGE 4-9, 5-3 5-3, 8-14 5-3, 8-20 5-3, 8-28, 8-29, 8-31 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM ITEM Rear brake Clutch Throttle lever Control cables Drive chain Wheels and tires Shift pedal Brake pedal Brake and clutch levers Chassis fasteners Instruments, lights and switches ROUTINE • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear, and replace if necessary. • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary. • Check hydraulic system for leakage. Correct if necessary. • Check operation, and correct if necessary. • Lubricate cable if necessary. • Check lever free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever housing if necessary. • Check cable free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate if necessary. • Check chain slack, and adjust if necessary. • Check chain condition. Lubricate if necessary. • Check wheel condition, and replace if damaged. • Check tire condition and tread depth. Replace if necessary. • Check air pressure. Correct if necessary. • Make sure that operation is smooth. • Correct if necessary. • Make sure that operation is smooth. Lubricate pedal pivoting point if necessary. • Make sure that operation is smooth. Lubricate lever pivoting points if necessary. • Make sure that all nuts, bolts and screws are properly tightened. • Check operation, and correct if necessary. 5-2 PAGE 5-3, 8-28, 8-29, 8-31 8-33 5-4, 8-27 8-37 5-4, 8-34, 8-36 5-4 8-39 8-39 8-38 5-6 5-6 5 U46D10E0.book Page 3 Thursday, June 11, 2009 12:59 PM ● EBU19541 Fuel Make sure that there is sufficient fuel in the tank. (See page 4-9.) ● EBU19560 Engine oil Make sure that the engine oil is at the specified level. Add oil as necessary. (See page 8-14.) 5 Check for correct brake pedal height. (See page 8-31.) If the pedal height is incorrect, have a Yamaha dealer adjust it. Check the operation of the lever and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have a Yamaha dealer check the brake system. Brake fluid level Check the brake fluid level. Add fluid if necessary. (See page 8-29.) EBU19631 Coolant Make sure that the coolant is at the specified level. Add coolant as necessary. (See page 8-20.) Recommended brake fluid: DOT 4 TIP The coolant level must be checked on a cold engine since the level varies with engine temperature. 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 there is any leakage, have a Yamaha dealer check the brake system. EBU19711 Front and rear brakes Brake lever and brake pedal ● Check that there is no free play in the brake lever. If there is free play, have a Yamaha dealer check the brake system. 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, check the brake pads for wear. (See page 8-28.) 5-3 U46D10E0.book Page 4 Tuesday, June 16, 2009 2:50 PM also cause the tire to dislodge from the rim under severe riding conditions. [EWB02541] Set tire pressures to the following specifications: EBU19761 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary. Recommended tire pressure: Front 27.5 kPa (0.275 kgf/cm², 4.0 psi) Rear 30.0 kPa (0.300 kgf/cm², 4.4 psi) Minimum tire pressure: Front 24.5 kPa (0.245 kgf/cm², 3.6 psi) Rear 27.0 kPa (0.270 kgf/cm², 4.0 psi) Maximum tire seating pressure: Front 250 kPa (2.5 kgf/cm², 36 psi) Rear 250 kPa (2.5 kgf/cm², 36 psi) EBU19770 Drive chain Check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the drive chain as necessary. (See page 8-34.) EBU19794 Tires Check tire pressure regularly to make sure it is at the recommended specifications. Also check for wear and damage. Tire pressure Use the low-pressure tire gauge to check and adjust tire pressures when the tires are cold. Tire pressures must be equal on both sides. WARNING! Operation of this vehicle with improper tire pressure may cause severe injury or death from loss of control or rollover. Tire pressure below the minimum specified could 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. 5-4 5 U46D10E0.book Page 5 Thursday, June 11, 2009 12:59 PM 1 5 1. Low-pressure tire gauge 1. Tire wear limit Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. Tire information This ATV is equipped with tubeless tires with valves. EWB02551 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an accident. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd. 5-5 U46D10E0.book Page 6 Thursday, June 11, 2009 12:59 PM EBU19850 Front: Manufacturer/model: DUNLOP/KT351 Radial Size: AT21 x 7R10 Type: Tubeless Rear: Manufacturer/model: DUNLOP/KT356 Radial Size: AT20 x 10R9 Type: Tubeless Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary. 5 Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. 5-6 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU19872 OPERATION 1. Set the parking brake. 2. Turn the key to “ON” and the engine stop switch to “ ”. The following warning lights should come on for a few seconds, then go off. ● Coolant temperature warning light ● Fuel level warning light ● Engine trouble warning light EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU19901 6 Read the Owner’s Manual carefully before riding the ATV. If there is a control or function you do not understand, ask your Yamaha dealer. ECB00824 NOTICE If a warning light does not go off, see page 4-2 for the corresponding warning light circuit check. To avoid possible damage, do not operate the ATV if a warning light stays on. EWB00631 WARNING Read the Owner’s Manual carefully to become familiar with all controls in order to help prevent any loss of control, which could cause an accident or injury. 3. Shift the transmission into neutral. The neutral indicator light should come on, if it does not come on, have a Yamaha dealer check the electrical circuit. EBU29483 Starting the engine ECB00150 TIP This model is equipped with an ignition circuit cutoff system. The engine can be started under the following conditions. ● The transmission is in neutral. NOTICE See the “Engine break-in” section on page 6-4 prior to operating the engine for the first time. 6-1 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM ● When it stops, it will be in first gear. Raise the pedal slightly to reach the neutral position, and then release the clutch. The clutch is disengaged with the transmission in gear. However, it is recommended to shift into neutral before starting the engine. 4. Completely close the throttle lever and start the engine by pushing the start switch. NOTICE: For maximum engine life, never accelerate hard when the engine is cold! 5 4 3 2 [ECB00162] TIP If the engine fails to start, release the start switch, then push it 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. N 1 2 6 1 1. Shift pedal 2. Neutral position EBU20592 To start out and accelerate 1. Release the throttle lever, apply the front or rear brake, and then release the parking brake. EBU20522 Shifting This ATV has a 5-speed forward transmission. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, release the throttle lever, apply the clutch, and then repeatedly depress the shift pedal until it stops. 6-2 U46D10E0.book Page 3 Thursday, June 11, 2009 12:59 PM ECB00200 EBU20650 To decelerate When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident. NOTICE Always close the throttle before shifting gears, otherwise damage to the engine and drive train may result. 6 2. Pull the clutch lever to disengage the clutch. 3. Shift into first gear, and then release the brake. 4. Open the throttle gradually and at the same time, release the clutch lever slowly. WARNING! Opening the throttle abruptly or releasing the clutch lever too quickly could make the ATV wheelie, which would increase the chance of an accident, including an overturn. [EWB00731] 5. Once the ATV has attained adequate speed, release the throttle, and at the same time, quickly pull in the clutch lever. 6. Shift the transmission into second gear. (Make sure not to shift the transmission into neutral.) 7. Open the throttle part way and gradually release the clutch lever. 8. Follow the same procedure when shifting to the next higher gear. EWB00710 WARNING Make sure the engine has sufficiently slowed before shifting to a lower gear. Engaging a lower gear when the engine speed is too high could make the wheels stop rotating and lose traction. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. ECB00180 NOTICE Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the ATV for long distances. The transmission is prop- ● 6-3 U46D10E0.book Page 4 Thursday, June 11, 2009 12:59 PM ● ances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. erly lubricated only when the engine is running. Inadequate lubrication may damage the transmission. Always use the clutch when changing gears. The engine, transmission and drive train are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch. 0–160 km (0–100 mi) or 0–10 hours Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position. 160–320 km (100–200 mi) or 10–20 hours Avoid prolonged operation above 3/4 throttle. Rev the engine through the gears freely, but do not use full throttle at any time. EBU20672 Engine break-in TIP ● For ATVs equipped with an odometer or an hour meter, follow the figures given in km (mi) or the figures given in hours. ● For ATVs not equipped with an odometer or hour meter, follow the figures given in hours. 320 km (200 mi) or 20 hours and beyond The ATV can now be operated normally. ECB00220 NOTICE If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. There is never a more important period in the life of your engine than the first 320 km (200 mi) or 20 hours of riding. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 320 km (200 mi) or 20 hours. The various parts in the engine wear and polish themselves to the correct operating clear- EBU26761 Parking When parking the ATV, shift into first gear, stop the engine, and then apply the parking brake. 6-4 6 U46D10E0.book Page 5 Thursday, June 11, 2009 12:59 PM Never park the ATV on hills that are too steep to walk up easily. 1. Bring the ATV to a stop by applying the front brake, shift into first gear, and then stop the engine. 2. With the front and rear brakes applied, apply the parking brake. 3. Release the front and rear brakes. 6 1. Parking brake lever (locked position) EBU20904 Parking on a slope EWB00851 WARNING Avoid parking on hills or other inclines. Parking on a hill or other incline could cause the ATV to roll out of control, increasing the chance of an accident. If you must park on an incline, place the ATV transversely across the incline, shift into first gear, stop the engine, apply the parking brake, and then block the front and rear wheels with rocks or other objects. 6-5 U46D10E0.book Page 6 Thursday, June 11, 2009 12:59 PM market products or having other modifications performed to your ATV that change any of the vehicle’s design or operation characteristics can put you and others at greater risk of serious injury or death. You are responsible for injuries related to changes in the vehicle. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● 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. EBU20910 Accessories and loading EBU20921 Genuine Yamaha Accessories Choosing accessories for your ATV is an important decision. Genuine Yamaha Accessories, which are available only from a Yamaha dealer, have been designed, tested, and approved by Yamaha for use on your ATV. Many companies with no connection to Yamaha manufacture parts and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies produce. Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha, even if sold and installed by a Yamaha dealer. Aftermarket parts, accessories, and modifications While you may find aftermarket products similar in design and quality to genuine Yamaha Accessories, recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others. Installing after6-6 6 U46D10E0.book Page 7 Thursday, June 11, 2009 12:59 PM ● EBU20941 Loading EWB00820 WARNING Never exceed the stated load capacity for this ATV. Overloading this ATV or carrying or towing cargo improperly could cause changes in ATV handling which could lead to an accident. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. ● ● ● 6 ● As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment as the stability and handling of an ATV can be changed. When adding accessories, keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable. ● ● ● MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): 100.0 kg (220 lb) 6-7 If you are carrying cargo and towing a trailer, include the tongue weight in the maximum ATV load limit. Load cargo on the carriers as close to the center of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it. 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. 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 2nd gear whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier ATV 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. U46D10E0.book Page 8 Thursday, June 11, 2009 12:59 PM EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 6 6-8 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU21132 RIDING YOUR ATV 7 7-1 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM ular attention to the safety information on pages 2-1–2-4. Also read all warning and notice labels on your ATV. EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. RIDE WITH CARE AND GOOD JUDGMENT EBU21596 Get training if you are inexperienced. EWB01381 GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by experienced operators only. 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 Owner’s Manual completely and understand the operation of the controls. Pay partic- ● ● WARNING Do not operate this ATV or allow anyone else to operate it without proper instruction. 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. Do not operate this ATV at speeds too fast for your skills or the conditions, as this increases your chances of losing control of the ATV and an accident. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. 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 tech7-2 7 U46D10E0.book Page 3 Thursday, June 11, 2009 12:59 PM niques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum performance until you are totally familiar with the ATV’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. 7 This ATV is designed to carry the operator only – passengers prohibited. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers. WARNING! Never carry a passenger. Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV. You could have an accident, resulting in severe injury or death to you and/or your passenger. [EWB01401] Not recommended for children under 16 years of age. EWB01390 WARNING A child under 16 should never operate an ATV with engine size greater than 90 cc. Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. 7-3 U46D10E0.book Page 4 Thursday, June 11, 2009 12:59 PM proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. [EWB01411] Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision. WARNING! Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. [EWB02611] 7 Apparel Always wear the following to reduce risk of injury in an accident: ● Approved motorcycle helmet that fits properly ● Eye protection (goggles, helmet face shield, or protective eyewear) ● Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident. WARNING! Operating without an ap- 7-4 U46D10E0.book Page 5 Thursday, June 11, 2009 12:59 PM 7 1. 2. 3. 4. 5. Protective clothing Goggles Gloves Boots Helmet Pre-operation checks Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. WARNING! Failure to inspect the ATV before operating it and to maintain it properly increases the possibility of an accident or equipment damage. [EWB01431] Do not operate after or while consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. Consuming alcohol or drugs could seriously affect your judgment, cause you to react more slowly, and affect your balance and perception. WARNING! Never consume alcohol or drugs before or while driving this ATV. You increase your chance of an accident. [EWB01421] Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a speed limiter. The speed limiter keeps the throttle from fully 7-5 U46D10E0.book Page 6 Thursday, June 11, 2009 12:59 PM ● 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 in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-5.) ● ● ● 2 1 ● Do not exceed the maximum loading limits for the vehicle (see box in this section or vehicle labeling). Make sure the load does not interfere with your control or ability to see where you are going. Reduce speed and allow more room to stop. A heavier vehicle takes longer to stop. Avoid hills and rough terrain. Choose terrain carefully. Use extreme caution when towing or carrying a load on inclines. Turn gradually and go slowly. As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories to carry cargo, you must use common sense and good judgment. 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. 1. Adjusting screw 2. Locknut Loading and accessories EWB00971 WARNING Improper loading or towing can increase the risk of loss of control, an overturn, or other accident. To reduce the risk of an accident: MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 100.0 kg (220 lb) 7-6 7 U46D10E0.book Page 7 Thursday, June 11, 2009 12:59 PM During operation Always keep your feet on the footrests during operation; otherwise, they may contact the rear wheels. WARNING! 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 footrest, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. [EWB02660] Avoid wheelies and jumping. WARNING! Attempting wheelies, jumps, and other stunts increases the chance of an accident, including an overturn. Never attempt stunts, such as wheelies or jumps. Don’t try to show off. [EWB01481] 7 Modifications and accessories Never modify this ATV through improper installation or use of accessories or other modification. All parts and accessories added to this ATV 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 7-7 U46D10E0.book Page 8 Thursday, June 11, 2009 12:59 PM other hot parts. Check under the vehicle after operating in areas where combustible materials may have collected. Do not idle or park the vehicle in long dry grass or other dry ground cover. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. questions, consult an authorized ATV dealer. WARNING! Operating this ATV with improper modifications may cause changes in handling which in some situations could lead to an accident. [EWB01491] Exhaust system EWB01501 ● ● WARNING Dry grass or brush or other combustible material accumulated around the engine area could catch fire. 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. Someone touching the exhaust system during or after operation could be burned. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it. 7 The muffler and other engine parts become extremely hot during operation and remain hot after the engine has stopped. To reduce the risk of fire during operation or after leaving the ATV, do not let brush, grass and other materials collect under the vehicle, near the muffler or exhaust pipe, or next to 7-8 U46D10E0.book Page 9 Thursday, June 11, 2009 12:59 PM BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control. Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. [EWB01511] ATVs on public streets, roads and highways. WARNING! Never operate this ATV on any public street, road or highway, even a dirt or gravel one. You could collide with another vehicle. [EWB01031] 7 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! The ATV could go out of control if you do not have enough time to react to hidden rocks, bumps, or holes. Go slowly and be extra care- Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. In many states it is illegal to operate 7-9 U46D10E0.book Page 10 Thursday, June 11, 2009 12:59 PM ful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. [EWB01531] 7 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. WARNING! You could collide with another vehicle if operating in off-road areas where you cannot easily be seen. Mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles. [EWB01061] Do not operate on 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. WARNING! Failure to use extra care when operating on excessively rough, slippery, or loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] 7-10 U46D10E0.book Page 11 Thursday, June 11, 2009 12:59 PM 7 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. Set the parking brake 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. As you get on the ATV, be sure not to accidentally move the shift pedal. With the engine idling, pull the clutch lever to disengage the clutch and shift into 1st gear, and then release the parking brake. Open the throttle gradually, and at the same time, release the clutch lever slowly. Once the ATV has attained adequate speed, release the throttle lever and at the same time, quickly pull in the clutch lever and shift into 2nd gear. Open the throttle part way and gradually release the clutch. WARNING! If the throttle is applied too abruptly or if the throttle is not released during shifting, or if the shift pedal is not released before applying the throttle, the front wheels may lift off the ground, resulting in a loss of directional con- Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. 7-11 U46D10E0.book Page 12 Thursday, June 11, 2009 12:59 PM trol. [EWB02631] NOTICE: Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. [ECB01071] Use this same procedure as you move into the higher gears. Be sure to coordinate the use of the throttle and shift pedal properly. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident. To achieve maximum traction while riding off-road, the two rear wheels 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. 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 footrest 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. TURNING YOUR ATV EWB01771 WARNING 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. ATV could go out of control, causing a collision or overturn. 7-12 7 U46D10E0.book Page 13 Thursday, June 11, 2009 12:59 PM 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. CLIMBING UPHILL EWB01591 7 WARNING Climbing hills improperly can cause overturns or loss of control. Use proper riding techniques described in this Owner’s Manual. ● Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. ● Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. ● Shift your weight forward. 1. Lean towards inside of turn. 2. Support your weight on the outer footrest. 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. Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. 7-13 U46D10E0.book Page 14 Thursday, June 11, 2009 12:59 PM ● ● ● ● Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 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, shift your weight to the uphill side of the ATV. 7 7-14 U46D10E0.book Page 15 Thursday, June 11, 2009 12:59 PM 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 footrests and leaning forward over the handlebars. Whenever possible, ride straight up hills. Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side – there could be another person, an obstacle, or a sharp drop-off. Use common sense and remember that some hills are too steep for you to climb or descend. 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. 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. 7 Do not attempt to climb hills until you have mastered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. To climb a hill, you need traction, momentum, and steady throttle. Travel fast enough to maintain momentum, but not so fast that you cannot react to changes in the terrain as you climb. 7-15 U46D10E0.book Page 16 Thursday, June 11, 2009 12:59 PM If you start to roll backwards, DO NOT apply the rear brake, and apply the front brake gradually. The ATV could easily tip over backwards. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount the ATV immediately on the 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. WARNING! Stalling, rolling backwards or improperly dismounting while climbing a hill could result in ATV overturning. If you cannot control the ATV, dismount immediately on the uphill side. [EWB01802] 7 7-16 U46D10E0.book Page 17 Thursday, June 11, 2009 12:59 PM 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. Choose a low gear which will allow the engine compression to do most of the braking for you. 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. Gradually apply only the rear brake. 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. EWB01131 7 WARNING Going down a hill improperly could cause overturns or loss of control. Always follow proper procedures for going down hills as described in this Owner’s Manual. ● Always check the terrain carefully before you start down any hill. ● Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. ● Shift your weight backward and to the up side of the hill. ● Never go down a hill at high speed. ● Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possible. ● Improper braking can cause the wheels on the uphill side to come off the ground or cause loss of traction. Gradually apply only the rear brake when going downhill. 7-17 U46D10E0.book Page 18 Thursday, June 11, 2009 12:59 PM ● ● ● Avoid crossing the side of a steep hill. 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 as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. 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. 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. CROSSING A SLOPE EWB01632 WARNING Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn. ● Always follow proper procedures as described in the Owner’s Manual. ● Avoid hills with excessively slippery or loose surfaces. 7-18 7 U46D10E0.book Page 19 Thursday, June 11, 2009 12:59 PM than the depth specified in your Owner’s Manual, as tires may float, increasing the risk of an overturn. The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. 7 CROSSING THROUGH SHALLOW WATER EWB01641 WARNING Operating this vehicle through deep or fastflowing water can lead to loss of control or an overturn. To reduce your risk of drowning or other injuries, use care when crossing through water. Never operate this ATV water deeper 7-19 U46D10E0.book Page 20 Thursday, June 11, 2009 12:59 PM Test your brakes after leaving the water. If necessary, apply them several times to let friction dry out the linings. Do not continue to ride your ATV without verifying that you have regained proper braking ability. WARNING! Wet brakes may have reduced stopping ability, which could cause loss of control. [EWB02621] Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. 1 1. Air filter case check hose RIDING OVER ROUGH TERRAIN EWB01651 WARNING Riding improperly over obstacles could cause loss of control or a collision. 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. 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. NOTICE: Undrained water can cause damage or improper operation. [ECB00841] 7-20 7 U46D10E0.book Page 21 Thursday, June 11, 2009 12:59 PM 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. 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 footrests at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01662 7 WARNING Skidding or sliding improperly may cause you to lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. ● 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. 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. 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. 7-21 U46D10E0.book Page 22 Thursday, June 11, 2009 12:59 PM 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 footrest to the outside of the turn. Position your weight over the front wheels for better control. (See page 7-12.) ● 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 page 7-12.) ● 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 page 7-21.) ● 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 page 7-13.) 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. WHAT TO DO IF... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. 7-22 7 U46D10E0.book Page 23 Thursday, June 11, 2009 12:59 PM ● ● 7 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 page 7-18.) 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 page 7-19.) EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 7-23 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU2164A PERIODIC MAINTENANCE AND ADJUSTMENT ● EBU21671 Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages. Running the engine while servicing can lead to eye injury, burns, fire, or carbon monoxide poisoning - possibly leading to death. See page 2-1 for more information about carbon monoxide. The intervals given in the periodic maintenance and lubrication chart should be considered as a general guide under normal riding conditions. However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED. EWB01841 WARNING Failure to properly maintain the vehicle or performing maintenance activities incorrectly may increase your risk of injury or death during service or while using the vehicle. If you are not familiar with vehicle service, have a Yamaha dealer perform the service. 8 EBU29571 Owner’s manual and tool kit Be sure to always keep the owner’s manual, the owner’s tool kit and the low-pressure tire gauge with the vehicle. Make sure to protect the owner’s manual by putting it in the plastic bag, then by placing the bag in the document pouch. EWB02561 WARNING Turn off the engine when performing maintenance unless otherwise specified. ● A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires. 8-1 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM 3 2 1 1. Owner’s manual 2. Low-pressure tire gauge 3. Owner’s tool kit 8 The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. TIP If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. 8-2 U46D10E0.book Page 3 Thursday, June 11, 2009 12:59 PM EBU21743 Periodic maintenance chart for the emission control system TIP ● 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. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL NO. 1 * ITEM Fuel line 2 * Spark plug 3 * 4 * Valves Crankcase breather system 5 * Exhaust system CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Check fuel hoses for cracks or other damage, and replace if necessary. • Replace. • Check condition and clean, regap, or replace if necessary. • Check valve clearance and adjust if necessary. • Check breather hose for cracks or other damage, and replace if necessary. • Check for leakage and replace gasket(s) if necessary. • Check for looseness and tighten all screw clamps and joints if necessary. 8-3 EVERY 6 6 12 2500 2500 5000 (1600) (1600) (3200) 160 160 320 √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ Every 5 years √ √ √ 8 U46D10E0.book Page 4 Thursday, June 11, 2009 12:59 PM INITIAL NO. 6 ITEM Spark arrester CHECK OR MAINTENANCE JOB Whichever comes first • Clean. 8 8-4 month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 EVERY 6 6 12 2500 2500 5000 (1600) (1600) (3200) 160 160 320 √ √ √ U46D10E0.book Page 5 Thursday, June 11, 2009 12:59 PM EBU21865 General maintenance and lubrication chart TIP ● 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. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) 20 80 hours 1 Air filter element • Clean and replace if necessary. • Check operation and adjust if necessary. • Check operation and correct if necessary. • Check fluid level and ATV for fluid leakage, and correct if necessary. • Replace brake pads. • Check operation and correct if necessary. • Check fluid level and ATV for fluid leakage, and correct if necessary. • Replace brake pads. 2 * Clutch 3 * Front brake 4 * Rear brake 8-5 EVERY 6 6 12 2500 2500 5000 (1600) (1600) (3200) 160 160 320 Every 20–40 hours (more often in wet or dusty areas) √ √ √ √ √ √ √ √ √ Whenever worn to the limit √ √ √ √ Whenever worn to the limit √ 8 U46D10E0.book Page 6 Thursday, June 11, 2009 12:59 PM INITIAL NO. 8 ITEM 5 * Brake hoses 6 * Parking brake 7 * Wheels 8 * Tires 9 * Wheel hub bearings 10 * Swingarm pivots 11 * Upper and lower arm pivots 12 Drive chain 13 * Drive chain roller 14 * Chassis fasteners CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 160 160 320 √ √ √ √ Every 4 years √ √ √ • Check for cracks or other damage, and replace if necessary. • Replace. • Check operation and adjust if necessary. • Check runout and for damage, and replace if necessary. • Check tread depth and for damage, and replace if necessary. • Check air pressure and balance, and correct if necessary. • Check for looseness or damage, and replace if necessary. • Check operation and for excessive play, and replace bearings if necessary. • Lubricate with lithium-soap-based grease. √ √ • Check chain slack and adjust if necessary. • Check rear wheel alignment and correct if necessary. • Clean and lubricate. • Check for wear and replace if necessary. • Make sure that all nuts, bolts, and screws are properly tightened. 6 6 12 2500 2500 5000 (1600) (1600) (3200) √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ • Lubricate with lithium-soap-based grease. 8-6 EVERY √ √ √ √ U46D10E0.book Page 7 Thursday, June 11, 2009 12:59 PM INITIAL NO. ITEM 15 * 16 * 17 * Shock absorber assemblies Rear suspension relay arm and connecting arm pivoting points Steering shaft 18 * Steering system CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ Engine oil 20 Engine oil filter element • Replace. √ * Cooling system • Check coolant level and ATV for coolant leakage, and correct if necessary. • Replace coolant. √ 22 * Moving parts and cables • Lubricate. 23 * Throttle lever housing and cable • Check operation and correct if necessary. • Check throttle cable free play and adjust if necessary. • Lubricate throttle lever housing and cable. 24 * Front and rear brake switches • Check operation and correct if necessary. 8-7 12 320 19 21 6 160 • Check operation and correct if necessary. Lubricate with lithium-soap-based grease. Check operation and repair or replace if damaged. Check toe-in and adjust if necessary. Change. Check ATV for oil leakage, and correct if necessary. 6 2500 2500 5000 (1600) (1600) (3200) 160 • Check operation and correct if necessary. • Check for oil leakage and replace if necessary. • • • • • EVERY √ 8 √ √ √ √ √ Every 2 years √ √ √ √ √ √ √ √ √ √ √ √ √ √ U46D10E0.book Page 8 Thursday, June 11, 2009 12:59 PM INITIAL NO. 25 * ITEM Lights and switches CHECK OR MAINTENANCE JOB Whichever comes first • Check operation and correct if necessary. • Adjust headlight beams. EVERY month 1 3 km (mi) 320 (200) 1300 (800) 6 6 12 hours 20 80 160 160 320 √ √ √ √ √ 2500 2500 5000 (1600) (1600) (3200) EBU29430 TIP Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● Replace the fuel hose every five years and if cracked or damaged. ● Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged. ● 8 8-8 U46D10E0.book Page 9 Thursday, June 11, 2009 12:59 PM EWB00011 1 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 2 EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1 2 1. Panel D 2. Panel E 3 EBU29533 8 Panel A To remove the panel 1. Remove the seat. (See page 4-11.) 2. Remove the fuel tank cap. (See page 4-8.) 3. Remove the bolts. 1. Panel A 2. Panel B 3. Panel C 8-9 U46D10E0.book Page 10 Thursday, June 11, 2009 12:59 PM 5. Install the fuel tank cap. 1 To install the panel 1. Remove the fuel tank cap. 2. Place the panel in the original position, and then install the quick fasteners. NOTICE: When installing the panel, be sure not to pinch the cables or wires. [ECB00381] 1 1 1 1. Bolt 4. Remove the quick fasteners, and then slide the panel backward and pull upward. 8 2 1. Projection 2. Slot 3. Install the bolts. 4. Install the fuel tank cap. 1 1. Quick fastener 8-10 U46D10E0.book Page 11 Thursday, June 11, 2009 12:59 PM Panels B and D To remove one of the panels 1. Remove panel A. 2. Pull the panel off. 2. Install panel A. Panel C To remove the panel 1. Remove panels A, B and D. 2. Remove the bolts, and then take the panel off. To install one of the panels 1. Place the panel in its original position. 8-11 8 U46D10E0.book Page 12 Thursday, June 11, 2009 12:59 PM To install the panel Place the panel in its original position, and then install the bolts. 1 Panel E To remove the panel 1. Remove panel A. 2. Remove the bolts, and then take the panel off. 1 1 1. Bolt 1 8 1 1. Bolt 1. Bolt 8-12 1 U46D10E0.book Page 13 Thursday, June 11, 2009 12:59 PM 1 dance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine. The porcelain insulator around the center electrode of the spark plug should be a medium-to-light tan (the ideal color when the vehicle is ridden normally). If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. If the spark plug shows signs of electrode erosion and excessive carbon or other deposits, it should be replaced. 1 1. Bolt To install the panel 1. Place the panel in the original position and install the bolts. 2. Install panel A. Specified spark plug: NGK/CR8E EBU29441 Before installing the spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. Checking the spark plug The spark plug is an important engine component, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- 8-13 8 U46D10E0.book Page 14 Tuesday, June 16, 2009 2:51 PM TIP If a torque wrench is not available when installing the spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. EBU29498 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart. 1. Spark plug gap Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) 8 To check the engine oil level 1. Place the ATV on a level surface. 2. Start the engine, warm it up until the engine oil has reached a normal temperature of 40 °C (104 °F), let it continue to idle for ten seconds or more, and then turn the engine off. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9.0 ft·lbf) 8-14 U46D10E0.book Page 15 Thursday, June 11, 2009 12:59 PM TIP To achieve the proper engine oil temperature for an accurate oil level reading, the engine must have first completely cooled down, and then warmed up again for several minutes to normal operating temperature. 1 1 2 3 3. Remove the engine oil tank filler cap, and wipe the engine oil dipstick off with a clean rag. 4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level. 4 5 1. 2. 3. 4. 5. TIP The engine oil should be between the minimum and maximum level marks. Engine oil tank filler cap Engine oil dipstick Maximum level mark Half-level mark Minimum level mark 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type through the engine oil tank filler hole to raise it to the correct level. NOTICE: Be sure the engine oil is at the correct level, otherwise engine damage may result. [ECB00851] 8-15 8 U46D10E0.book Page 16 Thursday, June 11, 2009 12:59 PM TIP When adding oil, be careful not to overfill the engine oil tank; the oil level rises faster starting from the half-level-portion on the dipstick. 6. Insert the dipstick into the engine oil tank filler hole, and then tighten the engine oil tank filler cap. NOTICE: Make sure that the engine oil tank filler cap is securely tightened; otherwise, oil may seep out when the engine is running. [ECB00362] 8 2 2 1 1. Engine guard 2. Bolt To change the engine oil (with or without oil filter element replacement) 1. Place the ATV on a level surface. 2. Remove the engine guard by removing the bolts. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Place an oil pan under the engine to collect the used oil. 5. Remove the engine oil tank filler cap, and then remove the engine oil tank drain bolt and its gasket. 8-16 U46D10E0.book Page 17 Tuesday, June 16, 2009 2:51 PM 2 1 1 2 1. Engine oil tank drain bolt 2. Gasket 1 1. Crankcase engine oil drain bolt 2. Gasket 6. Remove the crankcase engine oil drain bolt and its gasket. TIP Skip steps 7–10 if the oil filter element is not being replaced. 7. Remove the oil filter element cover by removing the bolts. 8-17 8 U46D10E0.book Page 18 Thursday, June 11, 2009 12:59 PM 1 2 1 2 2 1. Oil filter element cover 2. Bolt 1. Oil filter element 2. O-ring 8. Remove the oil filter element and the O-rings. 9. Install a new oil filter element and new Orings. 8 TIP Make sure that the O-rings are properly seated. 10. Install the oil filter element cover by installing the bolts, and then tighten them to the specified torque. Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 8-18 U46D10E0.book Page 19 Thursday, June 11, 2009 12:59 PM 11. Install the crankcase engine oil drain bolt, the engine oil tank drain bolt and their new gasket, and then tighten the bolts to their specified torques. TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. ECB00300 Tightening torques: Crankcase engine oil drain bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) Engine oil tank drain bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) NOTICE 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. ● 12. Refill with the specified amount of the recommended engine oil through the engine oil tank filler hole, and then install and tighten the engine oil tank filler cap. 8 Recommended oil: See page 10-1. Oil quantity: Without oil filter element replacement: 1.40 L (1.48 US qt, 1.23 Imp.qt) With oil filter element replacement: 1.45 L (1.53 US qt, 1.28 Imp.qt) 13. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 14. Turn the engine off, and then check the oil level and correct it if necessary. 8-19 U46D10E0.book Page 20 Thursday, June 11, 2009 12:59 PM 15. Install the engine guard by installing the bolts, and then tighten them to the specified torque. NOTICE: Be sure to apply LOCTITE® to the engine guard bolts before installing them. TIP The coolant level must be checked on a cold engine since the level varies with engine temperature. [ECB00371] 2. Check the coolant level in the coolant reservoir. Tightening torque: Engine guard bolt: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) TIP The coolant should be between the minimum and maximum level marks. EBU29860 Coolant 8 The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer change the coolant. WARNING! Never attempt to remove the radiator cap when the engine is hot. [EWB02670] 1 2 3 EBU23483 To check the coolant level 1. Place the ATV on a level surface. 1. Coolant reservoir cap 2. Maximum level mark 3. Minimum level mark 8-20 U46D10E0.book Page 21 Thursday, June 11, 2009 12:59 PM 3. If the coolant is at or below the minimum level mark, remove the coolant reservoir cap, add coolant or distilled water to the maximum level mark, and then install the reservoir cap. NOTICE: If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since they are harmful to the engine. If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not be protected against frost and corrosion. If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. [ECB01011] EBU26804 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean or, if necessary, replace the air filter element more frequently if you are riding in unusually wet or dusty areas. TIP 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. 8 1 Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt, 0.22 Imp.qt) TIP If the engine overheats, see page 8-51 for further instructions. 1. Air filter case check hose 1. Place the ATV on a level surface. 8-21 U46D10E0.book Page 22 Thursday, June 11, 2009 12:59 PM 2. Remove the seat. (See page 4-11.) 3. Remove the air filter case cover by unhooking the holders. 1 2 2 1 1. Wing bolt 2. Air filter element 8 6. Remove the wing bolt and washer from the air filter element. 7. Remove the sponge material from the air filter element frame. 1. Air filter case cover 2. Air filter case cover holder 4. Loosen the wing bolt. 5. Remove the air filter element together with the wing bolt and washer. 8-22 U46D10E0.book Page 23 Thursday, June 11, 2009 12:59 PM 2 1 1. Sponge material 2. Air filter element frame 10. Check the sponge material and replace it if damaged. 11. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material. 8. Wash the sponge material gently but thoroughly in solvent. WARNING! Always use parts cleaning solvent to clean the sponge material. Never use low-flash-point solvents or gasoline to clean the sponge material because the engine could catch fire or explode. [EWB01941] 9. Squeeze the excess solvent out of the sponge material and let it dry. NOTICE: Do not twist the sponge material when squeezing it. TIP The sponge material should be wet but not dripping. 12. Pull the sponge material over the air filter element frame. 13. Apply all-purpose grease to the air filter element seat. [ECB00441] 8-23 8 U46D10E0.book Page 24 Thursday, June 11, 2009 12:59 PM 1 1 8 1. Air filter element seat 1. Washer 14. Install the washer onto the air filter element frame, and then insert the wing bolt into the hole in the air filter element frame. NOTICE: Be sure to install the washer with the bent edge facing outward as shown. [ECB00452] 15. Insert the air filter element into the air filter case, and then tighten the wing bolt. NOTICE: Make sure that the air filter element is properly seated in the air filter case. Never operate the engine with the air filter element removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect the fuel injection system with subsequent poor performance and possible engine overheating. [ECB00761] 16. Install the air filter case cover by hooking the holders onto the air filter case. 8-24 U46D10E0.book Page 25 Thursday, June 11, 2009 12:59 PM 17. Install the seat. TIP The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions. Check the air filter case rubber joint to the throttle body and the rubber joint manifold fittings for an air-tight seal. Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine. 1 1. Bolt 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. EBU27702 Cleaning the spark arrester Select a well-ventilated area free of combustible materials and make sure the exhaust and muffler are cool. 1. Remove the bolt. 8-25 8 U46D10E0.book Page 26 Thursday, June 11, 2009 12:59 PM 1 2 2 1 1. Tailpipe 2. Spark arrester 8 1. Purging bolt 2. Gasket 7. Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel. 8. Stop the engine and allow the exhaust pipe to cool. 9. Check the gasket for damage, and replace it if necessary. 10. Install the gasket and the purging bolt, and then tighten the bolt to the specified torque. 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the bolt and tighten it to the specified torque. Tightening torque: Tailpipe bolt: 8 Nm (0.8 m·kgf, 5.8 ft·lbf) 6. Remove the purging bolt and the gasket. 8-26 U46D10E0.book Page 27 Thursday, June 11, 2009 12:59 PM The throttle cable free play should measure 2.0– 4.0 mm (0.08–0.16 in) at the throttle lever. Periodically check the throttle cable free play and, if necessary, adjust it as follows. 1. Slide the rubber cover back. 2. Loosen the locknut. 3. To increase the throttle cable free play, turn the throttle cable free play adjusting bolt in direction (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b). Tightening torque: Purging bolt: 27 Nm (2.7 m·kgf, 19 ft·lbf) EWB02380 WARNING Never run the engine in an enclosed area when purging the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poisoning, possibly leading to death, and start a fire. ● Always let the exhaust system cool prior to touching exhaust components. ● Always wear eye protection, and make sure no one is behind the ATV. ● Make sure there are no combustible materials in the area. (b) 1 (a) 8 2 3 EBU29700 Adjusting the throttle cable free play 4 The throttle cable free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. 1. 2. 3. 4. Rubber cover Throttle cable free play adjusting bolt Locknut Throttle cable free play 4. Tighten the locknut. 8-27 U46D10E0.book Page 28 Thursday, June 11, 2009 12:59 PM 5. Slide the rubber cover to its original position. EBU29560 Front brake pads Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. EBU24060 Valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. EBU29601 Brakes 1 Replacement of brake components requires professional knowledge. Brake service should be performed by a Yamaha dealer. 8 EWB02571 WARNING Operating with improperly serviced or adjusted brakes could lead to a loss in braking ability and an accident. 1. Wear indicator groove EBU24130 Checking the front and rear brake pads TIP The wheels need to be removed to check the brake pads. (See page 8-47.) The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. 8-28 U46D10E0.book Page 29 Thursday, June 11, 2009 12:59 PM EBU29831 EBU29500 Rear brake pads Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if 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. Front brake 1 8 1 1. Wear indicator groove 1. Minimum level mark 8-29 U46D10E0.book Page 30 Thursday, June 11, 2009 12:59 PM ● Rear brake ● 1 ● ● 1. Minimum level mark 8 TIP To check the rear brake fluid level, remove the seat. (See page 4-11.) Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause. EBU24291 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking. ● Oil seals: Replace every two years. ● Brake hoses: Replace every four years. Observe these precautions: ● When checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 8-30 U46D10E0.book Page 31 Thursday, June 11, 2009 12:59 PM The top of the brake pedal should be positioned 11.7 mm (0.46 in) below the top of the footrest as shown. If the brake pedal is not positioned as specified, have a Yamaha dealer adjust it. EBU24394 Checking the front brake lever free play The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake lever should have no free play as shown. If there is free play, have a Yamaha dealer check the brake system. 1 1 1. Brake pedal position EBU24711 Adjusting the parking brake free play 1. No brake lever free play The parking brake free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Cable length “A” should measure 47–51 mm (1.85–2.01 in). Adjust the parking brake free play as follows. EBU24612 Checking the brake pedal position The brake pedal position must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. 8-31 8 U46D10E0.book Page 32 Thursday, June 11, 2009 12:59 PM (a) 2 (b) 1 3 2 1 1. Adjusting bolt 2. Cable length “A” 3. Locknut 8 1. Locknut 2. Adjusting nut TIP If the cable length cannot be adjusted to specification, consult a Yamaha dealer. 1. Release the parking brake by moving the parking brake lever to the right. 2. Fully loosen the locknut and the adjusting bolt at the rear brake caliper. 3. Loosen the locknut on the brake cable. 4. Turn the adjusting nut on the brake cable in direction (a) to increase the cable length, and in direction (b) to decrease it. 5. Tighten the locknut on the brake cable. 6. Turn in the adjusting bolt at the rear brake caliper until it feels tight, then turn it out 1/8 turn and tighten its locknut to the specified torque. NOTICE: When tightening the locknut, hold the adjusting bolt with a wrench so that it does not turn together with the locknut. [ECB00521] 8-32 U46D10E0.book Page 33 Thursday, June 11, 2009 12:59 PM Turn the adjusting nut while holding the 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). Tightening torque: Locknut (rear brake caliper): 16 Nm (1.6 m·kgf, 11 ft·lbf) EWB02090 WARNING Operating with improperly serviced or adjusted brakes could cause the brakes to malfunction, resulting in reduced braking performance. This could increase the chance of a collision or accident. After adjusting the parking brake free play, block the rear of the ATV off the ground and spin the rear wheels. Check to make sure there is no brake drag. If brake drag is noticed, perform the adjustment again. 1 2 (a) (b) 8 1. Brake light switch 2. Brake light switch adjusting nut EBU24742 Brake light switches EBU29802 The brake light, which is activated by the brake pedal and brake lever, should come on just before braking takes effect. The brake light switch for the brake pedal can be adjusted as follows, but the front brake light switch should be adjusted by a Yamaha dealer. Adjusting the clutch lever free play The clutch lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The clutch lever free play should measure 8.0– 13.0 mm (0.31–0.51 in) as shown. If the free play is incorrect, adjust it as follows. 8-33 U46D10E0.book Page 34 Thursday, June 11, 2009 12:59 PM (a) 1 (a) (b) 1 2 (b) 2 1. Clutch lever free play 2. Clutch lever free play adjusting nut (clutch lever) 8 1. Locknut 2. Clutch lever free play adjusting nut (clutch cable) 1. To increase the clutch lever free play, turn the adjusting nut at the clutch lever in direction (a), and to decrease it, turn the nut in direction (b). If the specified free play cannot be obtained, proceed with the following steps. 2. Fully turn the adjusting nut at the clutch lever in direction (a) to loosen the clutch cable. 3. Loosen the clutch cable locknut, located towards the center of the cable. 4. To increase the clutch lever free play, turn the adjusting nut located towards the center of the cable in direction (a), and to decrease it, turn the nut in direction (b). 5. Tighten the locknut. TIP If the specified free play cannot be obtained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism. EBU26864 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. 8-34 U46D10E0.book Page 35 Thursday, June 11, 2009 12:59 PM To check the drive chain slack 1. Place the ATV on a level surface. 3. If the drive chain slack is incorrect, adjust it as follows. TIP When checking and adjusting the drive chain slack, there should be no weight on the ATV and all tires must be touching the ground. To adjust the drive chain slack 1. Place the ATV on a level surface. 2. Loosen the rear wheel axle pinch bolts. 3. Insert a rod of a diameter of 8 mm (0.3 in) and a length of 10 cm (4 in) into one of the holes in the drive chain tensioner as shown. 2. Move the ATV back and forth to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. 3 Drive chain slack: 25.0–35.0 mm (0.98–1.38 in) 8 4 1 2 1. 2. 3. 4. 1. Drive chain slack 8-35 Rear wheel axle pinch bolt Rod Drive chain tensioner Hole 1 1 U46D10E0.book Page 36 Thursday, June 11, 2009 12:59 PM TIP A rod can be obtained at a Yamaha dealer to make this adjustment. 4. Shift the transmission into neutral. 5. To tighten the drive chain, push the ATV backward. To loosen the drive chain, push the ATV forward. NOTICE: Improper drive chain slack will overload the engine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits. 3 1 2 4 Tightening torque: Rear axle pinch bolt: 21 Nm (2.1 m·kgf, 15 ft·lbf) [ECB00542] 8 6. Pull the rod out, and then tighten the rear axle pinch bolts to the specified torque in the order shown. EBU24882 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. 8-36 U46D10E0.book Page 37 Thursday, June 11, 2009 12:59 PM for the drive chain, as they may contain substances that could damage the Orings. [ECB00581] ECB00561 NOTICE The drive chain must be lubricated after washing the ATV or riding in the rain or wet areas. EBU24901 Checking and lubricating the cables 1. Clean the drive chain with kerosene and a small soft brush. NOTICE: To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents. [ECB00571] The operation and the condition of all control cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil 8 1 1. O-rings 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. NOTICE: Do not use engine oil or any other lubricants 8-37 U46D10E0.book Page 38 Thursday, June 11, 2009 12:59 PM EWB02581 ● ● 8 Recommended lubricants: Brake lever: Silicone grease Clutch lever: Lithium-soap-based grease WARNING Inspect cables frequently and replace if damaged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury. Always make sure all control cables work smoothly before you begin riding in cold weather. If the control cables are frozen or do not work smoothly, you could be unable to control the ATV, which could lead to an accident or collision. Brake lever EBU24922 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. 8-38 U46D10E0.book Page 39 Thursday, June 11, 2009 12:59 PM Clutch lever Recommended lubricant: Lithium-soap-based grease EBUM0170 Checking the shift pedal The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle. EBU24963 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bearings. EBU28871 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. 8-39 8 U46D10E0.book Page 40 Thursday, June 11, 2009 12:59 PM EBU24995 EBU25032 Lubricating the swingarm pivots 8 Lubricating the upper and lower arm pivots The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. The upper and lower arm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Lubricate the pivoting points using a grease gun. Recommended lubricant: Lithium-soap-based grease Recommended lubricant: Lithium-soap-based grease 8-40 U46D10E0.book Page 41 Thursday, June 11, 2009 12:59 PM Left side Right side 1 1 2 2 2 2 1. Upper grease nipple 2. Lower grease nipple 1. Upper grease nipple 2. Lower grease nipple EBU25103 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 8-41 8 U46D10E0.book Page 42 Thursday, June 11, 2009 12:59 PM EWB02160 WARNING Battery electrolyte is poisonous and dangerous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ignition away. Ventilate when charging or using in an enclosed space. KEEP OUT OF REACH OF CHILDREN. EBU29184 Battery 8 This model is equipped with a VRLA (Valve Regulated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened. ECB00620 NOTICE Never attempt to remove the battery cell seals, as this would permanently damage the battery. To remove the battery 1. Remove the seat. (See page 4-11.) 2. Remove the battery holding plate by removing the bolts. 8-42 U46D10E0.book Page 43 Thursday, June 11, 2009 12:59 PM 3. Disconnect the negative battery lead first, then the positive battery lead by removing their bolt. NOTICE: When removing the battery, the main switch must be off, and the negative lead must be disconnected before the positive lead. [ECB01001] To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electrical accessories. ECB00930 1 2 NOTICE To charge a VRLA (Valve Regulated Lead Acid) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charger, have a Yamaha dealer charge your battery. 1 4 3 1. 2. 3. 4. 8 To store the battery ● If the ATV will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. ● If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. Bolt Battery holding plate Negative battery lead (black) Positive battery lead (red) 4. Pull the battery out of its compartment. 8-43 U46D10E0.book Page 44 Thursday, June 11, 2009 12:59 PM ECB00940 NOTICE Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. 1 To install the battery TIP Be sure the battery is fully charged. 2 1. Place the battery in its compartment. 2. Connect the positive battery lead first, then connect the negative battery lead by installing their bolt. 1. Positive battery lead (red) 2. Negative battery lead (black) 3. Install the battery holding plate by installing the bolts. 4. Install the seat. (See page 4-11.) 8 8-44 U46D10E0.book Page 45 Thursday, June 11, 2009 12:59 PM 2. Remove the blown fuse, and then install a new fuse of the specified amperage. WARNING! Always use a fuse of the specified rating, and never use a substitute object in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical system, which could lead to a fire. [EWB02172] EBU25243 Replacing the fuse 1 Specified fuse: 20.0 A 2 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Fuse 2. Spare fuse The fuse holder is located under the seat. (See page 4-11.) If the fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off all electrical circuits. EBU29461 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove panel E. (See page 8-9.) 2. Remove the headlight bulb holder cover. ECB00640 NOTICE To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 8-45 8 U46D10E0.book Page 46 Thursday, June 11, 2009 12:59 PM 1 1 1. Headlight bulb holder cover 8 1. Headlight bulb holder 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the burnt-out bulb. 4. Place a new headlight bulb into position. NOTICE: 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. [ECB00651] 8-46 U46D10E0.book Page 47 Thursday, June 11, 2009 12:59 PM To lower a headlight beam, turn the adjusting bolt in direction (b). (a) 1 (b) 1. Do not touch the glass part of the bulb. 5. Install the headlight bulb holder by pushing it in and turning it clockwise. 6. Install the headlight bulb holder cover. 7. Install the panel. 8. Adjust the headlight beam if necessary. 1. Headlight beam adjusting bolt EBU26920 Tail/brake light This model is equipped with an LED type of tail/brake light. If the tail/brake light does not come on, have a Yamaha dealer check it. EBU25561 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. EBU25651 Removing a wheel 1. Place the ATV on a level surface. 2. Loosen the wheel nuts. To raise a headlight beam, turn the headlight beam adjusting bolt in direction (a). 8-47 8 U46D10E0.book Page 48 Thursday, June 11, 2009 12:59 PM Front 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. EBU25681 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts. TIP When installing a front wheel, make sure its arrow mark points toward the rotating direction of the wheel. ● When installing a rear wheel, make sure its wording “SIDE FACING OUTWARDS” faces outwards. ● 1. Wheel nut Rear 8 1. Wheel nut 8-48 U46D10E0.book Page 49 Thursday, June 11, 2009 12:59 PM Front 3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified torques. Tightening torques: Front wheel nut: 45 Nm (4.5 m·kgf, 32 ft·lbf) Rear wheel nut: 45 Nm (4.5 m·kgf, 32 ft·lbf) EBU25740 Troubleshooting 1. Arrow mark Although Yamaha ATVs receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself. However, should your ATV require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the ATV properly. Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills. Rear SID 1 CING OUTWAR DS E FA 1. “SIDE FACING OUTWARDS” 8-49 8 U46D10E0.book Page 50 Thursday, June 11, 2009 12:59 PM EWB02280 WARNING Do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe injury or property damage. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces. 8 8-50 U46D10E0.book Page 51 Thursday, June 11, 2009 12:59 PM EBU27691 Troubleshooting charts Starting problems or poor engine performance 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the ATV. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 8 3. Ignition Wet Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug. Operate the electric starter. Dry Have a Yamaha dealer check the ATV. The engine does not start. Check the battery. Remove the spark plug and check the electrodes. 4. Battery The engine turns over quickly. The battery is good. The engine turns over slowly. Check the battery lead connections, and charge the battery if necessary. Operate the electric starter. 8-51 The engine does not start. Have a Yamaha dealer check the ATV. U46D10E0.book Page 52 Thursday, June 11, 2009 12:59 PM Engine overheating EWB02290 WARNING Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening. Allow any remaining pressure to escape before completely removing the cap. The coolant level is low. Check the cooling system for leakage. Wait until the engine has cooled. Check the coolant level in the reservoir and radiator. The coolant level is OK. There is leakage. There is no leakage. Have a Yamaha dealer check and repair the cooling system. Add coolant. (See TIP.) Start the engine. If the engine overheats again, have a Yamaha dealer check and repair the cooling system. 8 TIP If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible. 8-52 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU25860 CLEANING AND STORAGE EBU25902 Cleaning Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV: 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 chain, sprockets or wheel axles. 3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job. WARNING! Wet brakes may have reduced stopping ability, increasing the chance of an accident. Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. [EWB02311] NOTICE: Excessive water pressure 4. 5. 6. 7. 8. 9-1 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. [ECB00711] Once most 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-reach places. Rinse the ATV off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbing cloth. Dry the chain and lubricate it to prevent it from rusting. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 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 cleaning, start the engine and let it idle for several minutes. 9 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM 3. Perform the following steps to protect the cylinder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark plug. b. Pour a teaspoonful of engine oil into the spark plug bore. c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. 4. Lubricate all control cables and the pivoting points of all levers and pedals. 5. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. EBU27261 Storage Short-term Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover. NOTICE: Storing the ATV in a poorly ventilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust. To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored. [ECB00721] 9 Long-term Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” section of this chapter. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorating. Specified amount: 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) 9-2 U46D10E0.book Page 3 Thursday, June 11, 2009 12:59 PM 6. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 7. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an excessively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page 8-42. TIP Make any necessary repairs before storing the ATV. 9 9-3 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 11.40 :1 Starting system: Electric starter Lubrication system: Dry sump Overall length: 1795 mm (70.7 in) Overall width: 1170 mm (46.1 in) Overall height: 1065 mm (41.9 in) Seat height: 810 mm (31.9 in) Wheelbase: 1270 mm (50.0 in) Ground clearance: 235 mm (9.3 in) Minimum turning radius: 3500 mm (138 in) Engine oil: Recommended brand: YAMALUBE Type: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W50 0 Weight: 10 30 70 90 110 130 ˚F 40 50 ˚C SAE 5W-30 With oil and fuel: 181.0 kg (399 lb) SAE 10W-30 Engine: 10 50 SAE 10W-40 Engine type: Liquid cooled 4-stroke, DOHC Cylinder arrangement: Forward-inclined single cylinder Displacement: 449 cm³ Bore × stroke: 95.0 × 63.4 mm (3.74 × 2.50 in) SAE 15W-40 SAE 20W-40 SAE 20W-50 –20 –10 0 10 20 30 Recommended engine oil grade: API service SG type or higher, JASO standard MA 10-1 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM Clutch: Engine oil quantity: Without oil filter element replacement: 1.40 L (1.48 US qt, 1.23 Imp.qt) With oil filter element replacement: 1.45 L (1.53 US qt, 1.28 Imp.qt) Clutch type: Wet, multiple-disc Transmission: Primary reduction system: Spur gear Primary reduction ratio: 61/23 (2.652) Secondary reduction system: Chain drive Secondary reduction ratio: 38/14 (2.714) Transmission type: Constant mesh 5-speed Operation: Left foot operation Gear ratio: 1st: 35/14 (2.500) 2nd: 30/15 (2.000) 3rd: 31/19 (1.632) 4th: 28/21 (1.333) 5th: 23/21 (1.095) Cooling system: Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt, 0.22 Imp.qt) Radiator capacity (including all routes): 1.25 L (1.32 US qt, 1.10 Imp.qt) Air filter: Air filter element: Wet element Fuel: Recommended fuel: Premium unleaded gasoline only Fuel tank capacity: 10.0 L (2.64 US gal, 2.20 Imp.gal) Fuel reserve amount: 3.4 L (0.90 US gal, 0.75 Imp.gal) Fuel injection: Throttle body: ID mark: 18P1 00 Spark plug (s): Manufacturer/model: NGK/CR8E Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) Chassis: Frame type: Aluminum die-cast and steel tube frame Caster angle: 4.0 ° 10-2 10 U46D10E0.book Page 3 Tuesday, June 16, 2009 2:51 PM Front wheel: Trail: 18.0 mm (0.71 in) Wheel type: Panel wheel Rim size: 10 x 5.5AT Front tire: Type: Tubeless Size: AT21 x 7R10 Manufacturer/model: DUNLOP/KT351 Radial Rear wheel: Wheel type: Panel wheel Rim size: 9 x 8.5AT Rear tire: Front brake: Type: Tubeless Size: AT20 x 10R9 Manufacturer/model: DUNLOP/KT356 Radial Type: Dual disc brake Operation: Right hand operation Recommended fluid: DOT 4 Loading: Rear brake: Maximum loading limit: 100.0 kg (220 lb) (Total weight of rider, cargo, accessories, and tongue) Type: Single disc brake Operation: Right foot operation Recommended fluid: DOT 4 Tire air pressure (measured on cold tires): 10 Recommended: Front: 27.5 kPa (0.275 kgf/cm², 4.0 psi) Rear: 30.0 kPa (0.300 kgf/cm², 4.4 psi) Minimum: Front: 24.5 kPa (0.245 kgf/cm², 3.6 psi) Rear: 27.0 kPa (0.270 kgf/cm², 4.0 psi) Front suspension: Type: Double wishbone Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 240 mm (9.5 in) 10-3 U46D10E0.book Page 4 Thursday, June 11, 2009 12:59 PM Rear suspension: Engine trouble warning light: LED Type: Swingarm (link suspension) Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 280 mm (11.0 in) Fuse: Fuse: 20.0 A Electrical system: Ignition system: TCI (digital) Charging system: AC magneto Battery: Model: YTZ7S Voltage, capacity: 12 V, 6.0 Ah Headlight: Bulb type: Krypton bulb Bulb voltage, wattage × quantity: Headlight: 12 V, 30/30 W × 2 Tail/brake light: LED Neutral indicator light: LED Fuel level warning light: LED Coolant temperature warning light: LED 10 10-4 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM EBU25981 CONSUMER INFORMATION EBU26012 EBU26020 Identification numbers Key identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key. Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1. Key identification number MODEL LABEL INFORMATION: EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame. 11 11-1 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM 1 1 1. Model label 1. Vehicle identification number EBU29662 TIP The vehicle identification number is used to identify your ATV. Vehicle Emission Control Information label The Vehicle Emission Control Information label is affixed at the location in the illustration. This label shows specifications related to exhaust emissions as required by federal law, state law and Environment Canada. EBU26050 Model label The model label is affixed at the location in the illustration. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 11 11-2 U46D10E0.book Page 3 Thursday, June 11, 2009 12:59 PM 1 1. Vehicle Emission Control Information label 11 11-3 U46D10E0.book Page 4 Thursday, June 11, 2009 12:59 PM EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of 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 11-4 U46D10E0.book Page 5 Thursday, June 11, 2009 12:59 PM EBU26080 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. MAINTENANCE INTERVAL month km (mi) hours 1 3 6 12 18 24 30 36 42 48 54 60 320 (200) 1300 (800) 2500 (1600) 5000 (3200) 7500 (4800) 10000 (6400) 12500 (8000) 15000 (9600) 17500 (11200) 20000 (12800) 22500 (14400) 25000 (16000) 20 80 160 320 480 640 800 960 1120 1280 1440 1600 DATE OF SERVICE MILEAGE 11 11-5 SERVICING DEALER NAME AND ADDRESS REMARKS U46D10E0.book Page 6 Thursday, June 11, 2009 12:59 PM EBU26501 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations. THE PERIOD OF WARRANTY for Yamaha ATVs shall be six (6) months from the date of purchase. DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will, free of charge, repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the product’s warranty period. All parts replaced under warranty become property of Yamaha Motor Corp. U.S.A. GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance, such as spark plugs, oil, oil filter, air filter, and brake shoes. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the ATV as specified in the appropriate owner’s manual; 2. Give notice to an authorized Yamaha ATV dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent purchaser(s), it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha ATV dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service. EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, USA also warrants to the ultimate purchaser and each subsequent purchaser of each 2006 and later model Yamaha ATV covered by this warranty that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty. All Models Thirty (30) months from the original purchase date YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555 Cypress, California 90630 11 11-6 U46D10E0.book Page 7 Thursday, June 11, 2009 12:59 PM WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes. If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write: Q. What are some examples of “abnormal” strain, neglect, or abuse? A. These terms are general and overlap each other in areas. Specific examples include: Running the machine out of oil, sustained high rpm, full-throttle, operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or careless transportation and or tie-down. If you have any specific questions on operation or maintenance, please contact your dealer for advice. YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT P.O. Box 6555 Cypress, California 90630 When contacting Yamaha Motor Corporation, U.S.A. don’t forget to include any important information such as names, addresses, model, V.I.N. (frame number), dates, and receipts. Q. Does the warranty cover incidental costs such as towing or transportation due to a failure? A. No. The warranty is limited to repair of the machine itself. CHANGE OF ADDRESS Q. May I perform any or all of the recommended maintenance shown in the Owner’s Manual instead of having the dealer do them? A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owner’s and Service Manual. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha ATV dealer. The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase. Q. Will the warranty be void or cancelled if I do not operate or maintain my new ATV exactly as specified in the Owner’s Manual? A. No. The warranty on a new ATV cannot be “voided” or “cancelled.” However, if a particular failure is caused by operation or maintenance other than as described in the Owner’s Manual, that failure may not be covered under warranty. 11 If you should move after you have purchased your new ATV, please advise us of your new address by sending a postcard listing your ATV model name, V.I.N. (frame number), dealer number (or dealer’s name) as it is shown on your warranty card, your name and new mailing address. Mail to: Q. What responsibility does my dealer have under this warranty? A. Each Yamaha ATV dealer is expected to: 1. Completely set up every new machine before sale. 2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date. 3. Each Yamaha ATV dealer is held responsible for his setup, service and warranty repair work. YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555 Cypress, California 90630 Attention: Warranty Department This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law. Q. Is the warranty transferable to second owners? A. Yes. The remainder of the existing warranty can be transferred upon request. The unit has to be inspected and re-registered by an authorized Yamaha ATV dealer for the policy to remain effective. 11-7 U46D10E0.book Page 8 Thursday, June 11, 2009 12:59 PM EBU26123 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Ser vice (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire Y.E.S. plan period. Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factor y-backed coverage for extra peace of mind. Y. E. S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, or 36 months beyond your warranty period. Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide. Y.E.S. is designed and administered by the same Yamaha people who handle your warranty – and it shows in the comprehensive coverage benefits. There are no mileage limitations. Coverage isn’t limited to “moving par ts” or the “drive train” like many other plans. And Y.E.S. covers manufacturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comfor ting uninterr upted factor ybacked protection can be. Y.E.S. coverage is transferable to a new owner if you sell or trade in your ATV. That can make your Yamaha much more valuable! This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service. You don’t have to pay anything for covered repairs. T h e r e ’s n o d e d u c t i b l e t o p ay, a n d r e p a i r s a r e n ’ t “pro-rated.” You don’t have any “out-of-pocket” expenses for covered repairs. 11 11-8 U46D10E0.book Page 9 Thursday, June 11, 2009 12:59 PM We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O. Box 6555 Cypress, CA 90630 11 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 11-9 U46D10E0.book Page 10 Thursday, June 11, 2009 12:59 PM EBU26132 11 11-10 U46D10E0.book Page 1 Thursday, June 11, 2009 12:59 PM INDEX A Accessories and loading ................................................ 6-6 Air filter element, cleaning ............................................ 8-21 Drive chain slack .......................................................... 8-34 E Engine break-in .............................................................. 6-4 Engine oil ....................................................................... 5-3 Engine oil and oil filter element .................................... 8-14 Engine, start ................................................................... 6-1 Engine stop switch ......................................................... 4-3 Engine trouble warning light ........................................... 4-3 B Battery .......................................................................... 8-42 Brake and clutch levers, checking and lubricating ....... 8-38 Brake fluid, changing .................................................... 8-30 Brake fluid level, checking ............................................ 8-29 Brake lever ..................................................................... 4-6 Brake lever free play, checking the front ...................... 8-31 Brake light switches ..................................................... 8-33 Brake pads, checking the front and rear ...................... 8-28 Brake pedal .................................................................... 4-6 Brake pedal, checking and lubricating ......................... 8-39 Brake pedal position, checking .................................... 8-31 Brakes .......................................................................... 8-28 Brakes, front and rear .................................................... 5-3 F Fuel ......................................................................... 4-9, 5-3 Fuel level warning light ................................................... 4-3 Fuel tank cap .................................................................. 4-8 Fuse, replacing ............................................................. 8-45 H Handlebar position, adjusting ....................................... 4-25 Handlebar switches ........................................................ 4-3 Headlight beam, adjusting ............................................ 8-47 Headlight bulb, replacing .............................................. 8-45 C Cables, checking and lubricating ................................. 8-37 Chassis fasteners ........................................................... 5-6 Cleaning ......................................................................... 9-1 Clutch lever .................................................................... 4-5 Clutch lever free play, adjusting ................................... 8-33 Coolant ..................................................................5-3, 8-20 Coolant temperature warning light ................................. 4-2 D Drive chain ..................................................................... 5-4 Drive chain, lubricating ................................................. 8-36 I Identification numbers .................................................. 11-1 Indicator light and warning lights .................................... 4-2 Instruments, lights and switches .................................... 5-6 K Key identification number ............................................. 11-1 L Label locations ............................................................... 1-1 Light switch .................................................................... 4-4 U46D10E0.book Page 2 Thursday, June 11, 2009 12:59 PM M Start switch .................................................................... 4-4 Steering shaft, lubricating ............................................ 8-41 Storage .......................................................................... 9-2 Suspension, lubricating the upper and lower arm pivots ......................................................................... 8-40 Swingarm pivots, lubricating ........................................ 8-40 Main switch .................................................................... 4-1 Maintenance and lubrication chart ................................. 8-5 Maintenance chart, emission control system ................. 8-3 Maintenance record ..................................................... 11-5 Model label ................................................................... 11-2 N Neutral indicator light ..................................................... 4-2 Noise regulation ........................................................... 11-4 O Owner’s manual and tool kit ........................................... 8-1 P Panels, removing and installing ..................................... 8-9 Parking ........................................................................... 6-4 Parking brake free play, adjusting ................................ 8-31 Parking brake lever ........................................................ 4-7 Parking on a slope ......................................................... 6-5 Part locations ................................................................. 3-1 R Riding your ATV ............................................................. 7-1 S Safety information .......................................................... 2-1 Seat .............................................................................. 4-11 Shifting ........................................................................... 6-2 Shift pedal ...................................................................... 4-8 Shift pedal, checking .................................................... 8-39 Shock absorber assemblies, adjusting the front .......... 4-11 Shock absorber assembly, adjusting the rear .............. 4-17 Spark arrester, cleaning ............................................... 8-25 Spark plug, checking .................................................... 8-13 Specifications ............................................................... 10-1 Speed limiter .................................................................. 4-5 T Tail/brake light ............................................................. 8-47 Throttle cable free play, adjusting ................................ 8-27 Throttle lever ........................................................... 4-4, 5-4 Tires ............................................................................... 5-4 Troubleshooting ........................................................... 8-49 Troubleshooting charts ................................................ 8-51 V Valve clearance ........................................................... 8-28 Vehicle Emission Control Information label ................. 11-2 Vehicle identification number ....................................... 11-1 W Warranty, extended ..................................................... 11-8 Warranty, limited .......................................................... 11-6 Wheel hub bearings, checking ..................................... 8-39 Wheel, installing ........................................................... 8-48 Wheel, removing .......................................................... 8-47 B6-yoko.fm Page 1 Wednesday, March 8, 2006 10:46 AM B6-yoko.fm Page 1 Wednesday, March 8, 2006 10:46 AM EBU26141 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 ON RECYCLED PAPER PRINTED IN JAPAN 2009.06-0.7×1 CR (E) DIC183