ATVs & Accessories - Yamaha - 2012 Yamaha Grizzly 550 4x4 EPS

READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM5FGB/YFM5FGHB YFM5FGPB/YFM5FGPHB WARNING LIT-11626-25-23 This ATV should not be ridden by anyone under 16 years of age. 1HS-F8199-10 DIC2342 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU17170 INTRODUCTION EBU17272 Congratulations on your purchase of the Yamaha YFM5FGB/YFM5FGHB/YFM5FGPB/YFM5FGPHB. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. 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. U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM 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. U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM 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. EBU17402 YFM5FGB/YFM5FGHB YFM5FGPB/YFM5FGPHB OWNER’S MANUAL ©2011 by Yamaha Motor Corporation, U.S.A. 1st edition, March 2011 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11626-25-23 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM 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 lights and warning lights .............. 4-2 Multi-function display .................................. 4-5 Handlebar switches .................................... 4-7 Throttle lever ............................................ 4-13 Speed limiter .............................................4-13 Front brake lever .......................................4-14 Brake pedal and rear brake lever .............4-14 Drive select lever ......................................4-15 Fuel tank cap ............................................4-15 Fuel ...........................................................4-16 Seat ..........................................................4-18 Storage compartments .............................4-19 Front carrier ..............................................4-22 Rear carrier ...............................................4-22 Adjusting the front and rear shock absorber assemblies ...............................4-22 Auxiliary DC jack .......................................4-23 PRE-OPERATION CHECKS ..........................5-1 Fuel .............................................................5-3 Engine oil ....................................................5-3 Final gear oil ...............................................5-3 Differential gear oil ......................................5-3 Coolant .......................................................5-3 Front and rear brakes .................................5-3 Throttle lever ...............................................5-4 Tires ............................................................5-4 Chassis fasteners .......................................5-6 Instruments, lights and switches .................5-7 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM OPERATION .................................................. 6-1 Starting the engine ..................................... 6-1 Operating the drive select lever and driving in reverse ...................................... 6-2 Engine break-in .......................................... 6-4 Parking ....................................................... 6-5 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.................................. 7-16 CROSSING A SLOPE............................... 7-17 CROSSING THROUGH SHALLOW WATER ................................................... 7-18 RIDING OVER ROUGH TERRAIN ........... 7-21 SLIDING AND SKIDDING......................... 7-21 WHAT TO DO IF... .................................... 7-22 WHAT TO DO... ........................................ 7-23 PERIODIC MAINTENANCE AND ADJUSTMENT................................................8-1 Owner’s manual and tool kit .......................8-2 Periodic maintenance chart for the emission control system ...........................8-3 General maintenance and lubrication chart ..........................................................8-5 Removing and installing panels ................8-10 Removing the radiator grills ......................8-20 Checking the spark plug ...........................8-20 Engine oil and oil filter cartridge ................8-22 Final gear oil .............................................8-27 Differential gear oil ....................................8-29 Coolant .....................................................8-32 Cleaning the air filter element ...................8-39 Cleaning the spark arrester ......................8-42 V-belt case drain plug ...............................8-44 Adjusting the throttle lever free play .........8-45 Valve clearance ........................................8-46 Adjusting the drive select lever safety system cable ...........................................8-46 Brakes .......................................................8-46 Checking the front and rear brake pads ...8-46 Checking the rear brake hose protectors ................................................8-47 Checking the brake fluid level ...................8-48 Changing the brake fluid ...........................8-49 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM Checking the front and rear brake lever free play ................................................. 8-50 Adjusting the brake pedal free play .......... 8-50 Axle boots ................................................ 8-52 Checking and lubricating the cables ........ 8-53 Checking and lubricating the front and rear brake levers .................................... 8-53 Checking and lubricating the brake pedal ...................................................... 8-54 Checking the wheel hub bearings ............ 8-55 Checking the stabilizer bushes ................ 8-55 Lubricating the rear knuckle pivots ........... 8-55 Lubricating the steering shaft ................... 8-56 Battery ...................................................... 8-56 Replacing a fuse ...................................... 8-59 Replacing a headlight bulb ....................... 8-61 Adjusting a headlight beam ...................... 8-63 Replacing the tail/brake light bulb ............ 8-63 Removing a wheel .................................... 8-64 Installing a wheel ...................................... 8-65 Troubleshooting ....................................... 8-66 Troubleshooting charts ............................. 8-67 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 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 1 23 4 10 9 8 6 5 7 5 1-1 11 12 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM 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 Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum front cargo limit of 99 lbs. lbs (45 :: 99 (45 kg) kg) NEVER sit on the carrier. Refer to instructions in the Owner's Manual. 1HP-F4877-U0 3 4 5880 N (600kgf) 1322 lbf 147 N ( 15kgf) 33 lbf Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum rear cargo limit of : 187 lbs (85 kg) : 187 lbs. (85 kg) NEVER sit on the carrier. Refer to instructions in the Owner's Manual. 37S-F151K-00 1HP-F4897-00 1-2 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM 5 6 1 WARNING 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 : 5.0 psi, (35 kPa) REAR : 4.4 psi, (30 kPa) • Minimum : FRONT : 4.6 psi, (32 kPa) REAR : 4.0 psi, (27 kPa) • Never set tire pressure below minimum.It could cause the tire to dislodge from the rim. LOADING/TRAILER TOWING • Cargo or a trailer can affect stability and handling. Read owner’s manual before loading or towing. • When riding with cargo or towing a trailer : Reduce speed and allow more room to stop. Avoid hills and rough terrain. • Maximum Vehicle Load : 485 lbs. (220 kg) Includes weight of operator, cargo and accessories (and if applicable, trailer tongue weight). This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. Do not incinerate, puncture or open. 1HP-F2259-01 7 1 lb (0.5 kg). 37S-F151F-U0 1HP-F816M-U0 1-3 U1HS10E0.book Page 4 Wednesday, April 13, 2011 10:29 AM 8 1 9 WARNING UNDER 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 1P0-F816L-00 4XE-F1568-00 1-4 U1HS10E0.book Page 5 Wednesday, April 13, 2011 10:29 AM 10 11 1 Turning the ATV in 4WD-LOCK (“DIFF.LOCK”) takes more effort. 5ND-F151E-00 5ND-F1558-00 12 Certification of Compliance This ATV complies with applicable provisions of ANSI/SVIA 1-2010 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. 37S-F817J-30 1-5 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU17431 SAFETY INFORMATION 2 ● EBU27233 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. U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM ● ● ● ● ● ● ● Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds 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. 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 range and maintain a 2 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM 2 ● ● ● ● ● steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings. ● ● ● ● Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Always use the size and type of tires specified in this manual. Always maintain proper tire pressure as described in this manual. Never modify an ATV through improper installation or use of accessories. Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. EWB00072 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 2-3 U1HS10E0.book Page 4 Wednesday, April 13, 2011 10:29 AM 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. 2 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 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 5 3 1. 2. 3. 4. 5. 6. 7. 8. 1. Rear shock absorber assembly spring preload adjusting ring 2. Rear storage compartment and tool kit 3. Fuel tank cap cover 4. Front shock absorber assembly spring preload adjusting ring 5. Spark plug 6. Brake pedal 7. V-belt case drain plug Radiator cap Battery Fuses Air filter case Spark arrester Engine oil dipstick Oil filter cartridge Coolant reservoir 3-1 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM EBU17712 TIP The ATV you have purchased may differ slightly from the figures shown in this manual. Controls and instruments 3 1. 2. 3. 4. 5. 6. 7. Drive select lever Rear brake lever Handlebar switches Rear brake fluid reservoir Multi-function display Front brake fluid reservoir On-Command four-wheel-drive/differential gear lock switch 8. Front brake lever 9. Throttle lever 10.Front storage compartment 11.Main switch 12.Auxiliary DC jack 3-2 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU17725 INSTRUMENT AND CONTROL FUNCTIONS EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 4 EBU29911 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 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM EBU26695 EBU17990 Indicator lights and warning lights Low-range indicator light “ ” This indicator light comes on when the transmission is in the low-range position. EBU17980 High-range indicator light “ ” This indicator light comes on when the transmission is in the high-range position. EBU17860 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. 1. On-Command differential gear lock indicator light “DIFF. LOCK” 2. Low-range indicator light “L” 3. High-range indicator light “H” 4. Neutral indicator light “N” 5. Reverse indicator light “R” 6. Park indicator light “P” 7. On-Command four-wheel-drive/differential gear lock indicator “ ”/“ ” 8. Engine trouble warning light “ ” 9. Coolant temperature warning light “ ” 10.Electric Power Steering warning light “EPS” (for EPS model) EBU17830 Reverse indicator light “ ” This indicator light comes on when the transmission is in the reverse position. EBU17970 Park indicator light “ ” This indicator light comes on when the transmission is in the park position. 4-2 4 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM ● EBU30530 4 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. 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. EBU30480 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. (See page 4-7 for an explanation of the self-diagnosis device.) 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. ECB00891 NOTICE ● The engine may overheat if the ATV is overloaded. In this case, reduce the load to specification. ● The engine may also overheat if mud or dirt has accumulated on the radiator (i.e., after riding in wet terrain). In this case, see page 8-20 for an explanation on how to access the radiator. EBU30570 Electric Power Steering warning light “EPS” (for EPS model) This warning light comes on when the key is turned to “ ” (on), and then goes off once the engine is started. If the warning light remains on or comes on 4-3 U1HS10E0.book Page 4 Wednesday, April 13, 2011 10:29 AM The On-Command differential gear lock indicator “ ” and the On-Command differential gear lock indicator light “DIFF. LOCK” come on when the On-Command differential gear lock switch is set to the “LOCK” position. after the engine is started, the EPS system may not be working correctly. When this occurs, have a Yamaha dealer check the EPS system. The electrical circuit of the warning light can be checked by turning the key to “ ” (on). If the warning light does not come on, have a Yamaha dealer check the electrical circuit. TIP ● Due to the synchronizing mechanism in the differential gear case, the four-wheel-drive indicator may not come on until the ATV starts moving. ● When the On-Command differential gear lock switch is set to “LOCK” or “4WD”, the indicator “ ” and the indicator light “DIFF. LOCK” will flash until the differential gear is completely locked or unlocked. If the indicator and the indicator light continue to flash, the differential is not completely locked or unlocked. In this case, start moving to allow time for the differential to lock or unlock. TIP ● If the engine is stopped using the engine stop switch and the key is in the “ ” (on) position, the EPS warning light comes on to indicate that the power assistance for the steering is not functioning. ● If the steering load is too heavy (i.e., excessive steering use when the ATV is traveling at a slow speed), the power assist is reduced to protect the EPS motor from overheating. EBU30450 On-Command four-wheel-drive indicator “ ”, On-Command differential gear lock indicator “ ” and indicator light “DIFF. LOCK” The On-Command four-wheel-drive indicator “ ” comes on when the On-Command four-wheeldrive switch is set to the “4WD” position. 4-4 4 U1HS10E0.book Page 5 Wednesday, April 13, 2011 10:29 AM ● EBU30490 Multi-function display ● ● Odometer and tripmeter modes Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the tripmeter modes “TRIP A” and “TRIP B” in the following order: ODO → TRIP A → TRIP B → ODO To reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button for at least three seconds. The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops. 4 1. 2. 3. 4. 5. 6. 7. an hour meter (which shows the total time the engine has been running) a fuel meter a self-diagnosis device “CLOCK” button “RESET” button “SELECT” button Speedometer Fuel meter Clock/Hour meter Odometer/Tripmeter A/Tripmeter B TIP Pushing and holding in the “SELECT” button, and turning the key to “ ” (on) while the button is pushed, switches the display between “mph” and “km/h”. The multi-function display is equipped with the following: ● a speedometer ● an odometer ● two tripmeters (which show the distance traveled since they were last set to zero) ● a clock 4-5 U1HS10E0.book Page 6 Wednesday, April 13, 2011 10:29 AM Clock mode Pushing the “CLOCK” button switches the display between the clock mode “CLOCK” and the hour meter mode “HOUR” in the following order: CLOCK → HOUR → CLOCK TIP This fuel meter is equipped with a self-diagnosis system. If the electrical circuit is not working correctly, all the display segments and fuel level warning indicator will start flashing. If this occurs, have a Yamaha dealer check the electrical circuit. To set the clock 1. Set the display to the clock mode. 2. Push the “SELECT” button and “RESET” button together for at least three seconds. 3. When the hour digits start flashing, push the “RESET” button to set the hours. 4. Push the “SELECT” button, and the minute digits will start flashing. 5. Push the “RESET” button to set the minutes. 6. Push the “SELECT” button and then release it to start the clock. 4 Fuel meter The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear from “F” (full) towards “E” (empty) as the fuel level decreases. When the “E” segment disappears and the fuel level warning indicator flashes, refuel as soon as possible. 1. Fuel level warning indicator 2. Fuel meter 3. “E” segment 4-6 U1HS10E0.book Page 7 Wednesday, April 13, 2011 10:29 AM Self-diagnosis device EBU18061 Handlebar switches 4 1. Error code display 1. 2. 3. 4. This model is equipped with a self-diagnosis device for various electrical circuits. If a problem is detected in any of those circuits, the multi-function display will indicate an error code. If the multi-function display indicates an error code, note the code number, and then have a Yamaha dealer check the vehicle. Light switch “ / /OFF” Start switch “ ” Engine stop switch “ / ” Override switch “OVERRIDE” 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 to stop the engine in an emergency situation. The engine will not start or run when this switch is set to “ ”. ECB00811 NOTICE If the multi-function display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage. 4-7 U1HS10E0.book Page 8 Wednesday, April 13, 2011 10:29 AM EBU18101 EBU18190 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. Override switch “OVERRIDE” EBU18154 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. 4 ECB00043 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 8-56.) 1. Override switch “OVERRIDE” Top speed is normally limited when operating in differential gear lock. If conditions require more engine power when riding forward, push and hold this switch to override the differential gear lock speed limiting function. (See page 4-10.) Releasing the switch restores the speed limiting function. While the override switch is pushed, the segments of the speedometer digits will appear as shown in the figure. 4-8 U1HS10E0.book Page 9 Wednesday, April 13, 2011 10:29 AM es with the riding speed. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. EBU26606 On-Command four-wheel-drive switch “2WD”/“4WD” 4 EWB00163 WARNING Always stop the ATV before changing from two-wheel drive to four-wheel drive and vice versa. The ATV handles differently in twowheel drive than in four-wheel drive in some circumstances. Changing from two-wheel drive to four-wheel drive or vice versa while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and increase the risk of losing control and of causing an accident. TIP If the digits of the speedometer appear as shown when the switch is NOT being pushed, this could indicate a malfunction in the electrical system. In this case, take the ATV to a Yamaha dealer at the first opportunity. EWB00150 WARNING Always ride at a slow speed when the ATV is in four-wheel-drive differential gear lock, and allow extra time and distance for maneuvers. All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The effort needed to turn increas- This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice versa. Select the appropriate drive according to the terrain and the conditions. ● “2WD” (two-wheel drive): Power is supplied to the rear wheels. 4-9 U1HS10E0.book Page 10 Wednesday, April 13, 2011 10:29 AM ● “4WD” (four-wheel drive): Power is supplied to the rear and front wheels. To change from two-wheel drive to four-wheel drive, stop the ATV and push the switch in to the “4WD” position. Then, the four-wheel-drive indicator “ ” comes on in the multi-function display. To change from four-wheel drive to two-wheel drive, stop the ATV and push the switch in to the “2WD” position. EBU30461 On-Command differential gear lock switch “4WD”/“LOCK” EWB00131 WARNING Always stop the ATV before changing from four-wheel drive to four-wheel-drive differential gear lock or vice versa. The ATV handles differently in four-wheel drive than in differential gear lock in some circumstances. Changing from four-wheel drive to differential gear lock or vice versa while moving may cause the ATV to handle differently unexpectedly. This could distract the operator and increase the risk of losing control and causing an accident. 1 2WD 4WD 1. On-Command four-wheel-drive switch “2WD”/“4WD” 4-10 4 U1HS10E0.book Page 11 Wednesday, April 13, 2011 10:29 AM EWB00140 4 2 WARNING Always ride at a slow speed when the ATV is in differential gear lock, and allow extra time and distance for maneuvers. All wheels turn at the same speed when the differential gear is locked, so it takes more effort to turn the ATV. The effort needed to turn increases with the riding speed. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. 1 2WD 4WD 1. On-Command four-wheel-drive switch “2WD”/“4WD” 2. On-Command differential gear lock switch “4WD”/“LOCK” This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive. Select the appropriate switch position according to the terrain and the conditions. ● “4WD” (four-wheel drive): Power is supplied to the rear and front wheels. ● “LOCK” (four-wheel drive with the differential gear locked): Power is supplied to the rear and front wheels and the differential gear is locked. Unlike in four-wheel drive, all wheels turn at the same speed. To lock the differential gear in four-wheel drive, make sure the On-Command four-wheel-drive switch is pushed in to the “4WD” position. 4-11 U1HS10E0.book Page 12 Wednesday, April 13, 2011 10:29 AM 1 1 2 2WD LOCK 4WD 4WD (a) 4 1. Differential gear lock lever 2. On-Command four-wheel-drive switch “2WD”/“4WD” 1. On-Command differential gear lock switch “4WD”/“LOCK” To unlock the differential gear, stop the ATV and push the switch to the “4WD” position. Stop the ATV, move the differential gear lock lever to position (a), and then push the differential gear lock switch in to the “LOCK” position. When the differential gear is locked, the differential gear lock indicator light “DIFF. LOCK” will come on along with the indicator “ ” in the multi-function display. TIP ● When the switch is set to “LOCK” or “4WD”, the differential gear lock indicator and indicator light will flash until the differential gear is completely locked or unlocked. ● When the indicator and indicator light are flashing, turning the handlebar back and forth will help the differential gear lock to engage or disengage. 4-12 U1HS10E0.book Page 13 Wednesday, April 13, 2011 10:29 AM ● ● 4 Riding before the differential gear is properly engaged or disengaged (e.g., when the indicator and indicator light are flashing) will cause the vehicle speed to be limited until the differential gear is completely engaged or disengaged. When the ATV is in four-wheel-drive differential gear lock, the maximum traveling speed is limited to 35 km/h (22 mi/h). However, if conditions require full engine power to be available, push and hold the override switch to disable the differential gear lock speed limiter. (See page 4-8 for a detailed explanation of this switch.) 2WD 4WD 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. 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. EBU18323 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 de4-13 U1HS10E0.book Page 14 Wednesday, April 13, 2011 10:29 AM crease 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 3.0–5.0 mm (0.12–0.20 in). (See page 8-45.) 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] EBU18391 Front brake lever The front brake lever is located on the right handlebar. To apply the front brake, pull the brake lever toward the handlebar grip. 4 3 2 1 (b) 1. Front brake lever EBU18442 Brake pedal and rear brake lever (a) The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in) 3. Tighten the locknut. 4-14 U1HS10E0.book Page 15 Wednesday, April 13, 2011 10:29 AM EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-2 for the drive select lever operation. 4 1. Brake pedal 1. Drive select lever EBU27350 Fuel tank cap To remove the fuel tank cap Open the fuel tank cap cover, and then remove the fuel tank cap by turning it counterclockwise. 1. Rear brake lever 4-15 U1HS10E0.book Page 16 Wednesday, April 13, 2011 10:29 AM To install the fuel tank cap Install the fuel tank cap by turning it clockwise until a click is heard, and then close the fuel tank cap cover. EBU18731 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. Fuel tank cap cover 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 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 1. Fuel tank cap 4-16 4 U1HS10E0.book Page 17 Wednesday, April 13, 2011 10:29 AM expands when it heats up, heat from the engine or the sun can cause fuel to spill out of the fuel tank. 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 4 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. 1. Maximum fuel level 2. Fuel tank filler tube Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 20.0 L (5.28 US gal, 4.40 Imp.gal) Fuel reserve amount: 4.5 L (1.19 US gal, 0.99 Imp.gal) ECB00070 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. 4-17 U1HS10E0.book Page 18 Wednesday, April 13, 2011 10:29 AM Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 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. 4 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. 1. Seat 2. 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. EBU18881 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear. 4-18 U1HS10E0.book Page 19 Wednesday, April 13, 2011 10:29 AM The front storage compartment is located at the front right side of the ATV. To access the storage compartment, remove the storage compartment cover by turning it counterclockwise. 4 1. Projection 2. Seat holder EBU27362 Storage compartments 1. Front storage compartment cover This ATV is equipped with two storage compartments. ECB00830 NOTICE Do not store metal or sharply edged objects, like tools, in the storage compartments. If they must be stored, wrap them in appropriate cushion material to prevent damaging the storage compartments. 4-19 U1HS10E0.book Page 20 Wednesday, April 13, 2011 10:29 AM 4 1. Front storage compartment 1. Rear storage compartment cover The rear storage compartment is located under the seat. (See page 4-18.) To access the storage compartment, remove the storage compartment cover. 1. Rear storage compartment 4-20 U1HS10E0.book Page 21 Wednesday, April 13, 2011 10:29 AM 4 When storing any documents in the storage compartments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartments. ● Do not exceed the load limit of 0.5 kg (1 lb) for the front storage compartment or 2.0 kg (4 lb) for the rear storage compartment. ● Do not exceed the maximum load of 220.0 kg (485 lb) for the ATV. TIP A drain plug is fitted at the bottom of each storage compartment. If any water collects in a storage compartment, remove the drain plug, drain the water, and then install the drain plug. 1. Storage compartment drain plug 1. Storage compartment drain plug 4-21 U1HS10E0.book Page 22 Wednesday, April 13, 2011 10:29 AM Adjust the spring preload as follows. Turn the spring preload adjusting ring 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. Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. EBU18962 Front carrier ● ● Do not exceed the load limit of 45.0 kg (99 lb) for the front carrier. Do not exceed the maximum load of 220.0 kg (485 lb) for the ATV. EBU18972 Rear carrier ● ● Do not exceed the load limit of 85.0 kg (187 lb) for the rear carrier. Do not exceed the maximum load of 220.0 kg (485 lb) for the ATV. EBU30470 Adjusting the front and rear shock absorber assemblies The spring preload can be adjusted to suit the rider’s weight and the riding conditions. EWB00400 1. Spring preload adjusting ring 2. Position indicator WARNING 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. TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-22 4 U1HS10E0.book Page 23 Wednesday, April 13, 2011 10:29 AM Shock absorber cylinder damage could also result in poor handling which could cause an accident. ● 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. ● Do not deform or damage the cylinder in any way. ● 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. Special wrench Spring preload setting: Minimum (soft): 1 Standard: 2 Maximum (hard): 5 EBU19183 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running and the light switch is set to “OFF”. 1. Set the light switch to “OFF”. 2. Turn the accessory off. 3. Start the engine. (See page 6-1.) 4. Open the auxiliary DC jack cap, and then insert the accessory power plug into the jack. EWB02730 WARNING The rear shock absorber assembly contains highly pressurized nitrogen gas. If the shock absorber assembly is damaged, it could explode causing injury or property damage. 4-23 U1HS10E0.book Page 24 Wednesday, April 13, 2011 10:29 AM Maximum rated capacity for the auxiliary DC jack: DC 12 V, 10 A (120 W) 5. Turn the accessory on. 6. When the auxiliary DC jack is not being used, cover it with the cap. ECB00120 NOTICE ● Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. ● If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult. ● Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged. 1. Auxiliary DC jack cap 1. Auxiliary DC jack 4-24 4 U1HS10E0.book Page 25 Wednesday, April 13, 2011 10:29 AM EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 4 4-25 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM 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 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 ROUTINE PAGE Fuel • Check fuel level in fuel tank, and add recommended fuel if necessary. • Check fuel line for leakage. Correct if necessary. 4-16, 5-3 Engine oil • Check oil level in engine, and add recommended oil to specified level if necessary. • Check ATV for oil leakage. Correct if necessary. 5-3, 8-22 Final gear oil • Check ATV for oil leakage. Correct if necessary. 5-3, 8-27 Differential gear oil • Check ATV for oil leakage. Correct if necessary. 5-3, 8-29 Coolant • Check coolant level in reservoir, and add recommended coolant to specified level if necessary. • Check cooling system for leakage. Correct if necessary. 5-3, 8-32 5-1 5 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM ITEM ROUTINE PAGE Front brake • 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 specified brake fluid to specified level if necessary. • Check hydraulic system for leakage. Correct if necessary. 5-3, 8-46, 8-48, 8-50 Rear brake • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check pedal free play, and adjust if necessary. • Check brake pads for wear, and replace if necessary. • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary. • Check hydraulic system for leakage. Correct if necessary. 5-3, 8-46, 8-48, 8-50, 8-50 Throttle lever • Make sure that operation is smooth. Lubricate cable and lever housing if necessary. • Check lever free play, and adjust if necessary. 5-4, 8-45 Control cables • Make sure that operation is smooth. Lubricate if necessary. 8-53 Wheels and tires • Check wheel condition, and replace if damaged. • Check tire condition and tread depth. Replace if necessary. • Check air pressure. Correct if necessary. 5-4 Brake pedal • Make sure that operation is smooth. Lubricate pedal pivoting point if necessary. 8-54 Brake levers • Make sure that operation is smooth. Lubricate lever pivoting points if necessary. 8-53 Axle boots • Check for cracks or damage, and replace if necessary. 8-52 Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. 5-6 Instruments, lights and switches • Check operation, and correct if necessary. 5-7 5 5-2 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM EBU19541 TIP The coolant level must be checked on a cold engine since the level varies with engine temperature. Fuel Make sure that there is sufficient fuel in the tank. (See page 4-16.) EBU19560 Engine oil EBU29082 Front and rear brakes Make sure that the engine oil is at the specified level. Add oil as necessary. (See page 8-22.) Brake levers and brake pedal ● Check that there is no free play in the front and rear brake levers. If there is free play, have a Yamaha dealer check the brake system. ● Check for correct free play in the brake pedal. If the free play is incorrect, adjust it. (See page 8-50.) ● Check the operation of the brake levers and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have a Yamaha dealer check the brake system. EBU19590 Final gear oil Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-27.) EBU19600 Differential gear oil Make sure that the differential gear oil is at the specified level. Add oil as necessary. (See page 8-29.) EBU19631 Coolant Brake fluid level Check the brake fluid level. Add fluid if necessary. (See page 8-48.) Make sure that the coolant is at the specified level. Add coolant as necessary. (See page 8-32.) 5-3 5 U1HS10E0.book Page 4 Wednesday, April 13, 2011 10:29 AM EBU19814 Specified brake fluid: DOT 4 5 Tires Check tire pressure regularly to make sure it is at the recommended specifications. Also check for wear and damage. 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 a lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be checked by a Yamaha dealer. 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 also cause the tire to dislodge from the rim under severe riding conditions. [EWB02541] Set tire pressures to the following specifications: 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 8-46.) 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. 5-4 U1HS10E0.book Page 5 Wednesday, April 13, 2011 10:29 AM Recommended tire pressure: Front 35.0 kPa (0.350 kgf/cm², 5.0 psi) Rear 30.0 kPa (0.300 kgf/cm², 4.4 psi) Minimum tire pressure: Front 32.0 kPa (0.320 kgf/cm², 4.6 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) 5 1. Low-pressure tire gauge Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. 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. 5-5 U1HS10E0.book Page 6 Wednesday, April 13, 2011 10:29 AM Front: Manufacturer/model: MAXXIS/MU19 Size: AT25 x 8-12 Type: Tubeless Rear: Manufacturer/model: MAXXIS/MU20 Size: AT25 x 10-12 Type: Tubeless 5 1. Tire wear limit Tire information This ATV is equipped with tubeless tires with valves. 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. 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 Manufacturing Corporation of America. EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. 5-6 U1HS10E0.book Page 7 Wednesday, April 13, 2011 10:29 AM EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary. 5 5-7 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU19873 OPERATION 1. 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 ● Engine trouble warning light The EPS warning light should come on, then go off when the engine is started. (for EPS model) 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 EWB00631 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. 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. 2. Apply the brake pedal, and then shift the drive select lever into the neutral or park position. The corresponding indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. EBU30560 Starting the engine ECB00150 NOTICE See the “Engine break-in” section on page 6-4 prior to operating the engine for the first time. 6-1 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM ECB00163 TIP This model is equipped with an ignition circuit cutoff system. The engine can be started under the following conditions: ● The drive select lever is in the neutral or park position. ● The rear brake lever or brake pedal is applied with the drive select lever in any position. However, it is recommended to shift into the neutral or park position before starting the engine. NOTICE For maximum engine life, never accelerate hard when the engine is cold! EBU20441 Operating the drive select lever and driving in reverse ECB00170 NOTICE Before shifting, stop the ATV, otherwise the transmission may be damaged. 3. Apply the rear brake lever or brake pedal. 4. Completely close the throttle lever and start the engine by pushing the start switch. Shifting: Neutral to High-range and High-range to Low-range 1. Bring the ATV to a complete stop. 2. Apply the brake pedal, and then shift by moving the drive select lever along the shift guide. 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. TIP Make sure that the drive select lever is completely shifted into position. 6-2 6 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM 6 1. 2. 3. 4. 5. 6. L 2 H 3 N 4 R 5 P 6 reverse, make sure there are no people or obstacles behind you. When it is safe to proceed, go slowly. 1. Bring the ATV to a complete stop. 2. Apply the brake pedal. The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal. 3. Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide. Drive select lever L (Low-range) H (High-range) N (Neutral) R (Reverse) P (Park) 3. Release the brake pedal, and then open the throttle lever gradually. Shifting: Neutral to Reverse and Reverse to Park EWB00720 WARNING Improper operation in reverse could make you hit an obstacle or even a person behind you, resulting in serious injury. When you shift into 6-3 U1HS10E0.book Page 4 Wednesday, April 13, 2011 10:29 AM 1. 2. 3. 4. 5. 6. L 2 H 3 N 4 R 5 P 6 4. Check behind for people or obstacles, and then release the brake pedal. 5. Open the throttle lever gradually and continue to watch to the rear while backing. EBU20682 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. Drive select lever L (Low-range) H (High-range) N (Neutral) R (Reverse) P (Park) 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 clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. TIP ● When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. ● Due to the synchronizing mechanism in the engine, the indicator light may not come on until the ATV starts moving. 6-4 6 U1HS10E0.book Page 5 Wednesday, April 13, 2011 10:29 AM 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. EBU29900 Parking on a slope EWB00860 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, stop the engine, shift the drive select lever to the park position, and then block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily. 160–320 km (100–200 mi) or 10–20 hours Avoid prolonged operation above 3/4 throttle. Rev the engine freely, but do not use full throttle at any time. 6 320 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. 1. Bring the ATV to a stop by applying the brakes. 2. Stop the engine. 3. With the brake pedal applied, shift the drive select lever to the park position. EBU27321 Parking When parking the ATV, stop the engine, and shift the drive select lever into the park position. 6-5 U1HS10E0.book Page 6 Wednesday, April 13, 2011 10:29 AM 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 aftermarket 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 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 6-6 6 U1HS10E0.book Page 7 Wednesday, April 13, 2011 10:29 AM ● ● 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. MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): 220.0 kg (485 lb) Front carrier: 45.0 kg (99 lb) Rear carrier: 85.0 kg (187 lb) Front storage compartment: 0.5 kg (1 lb) Rear storage compartment: 2.0 kg (4 lb) Trailer hitch: Pulling load (total weight of trailer and cargo): 5880 N (600 kgf, 1322 lbf) Tongue weight (vertical weight on trailer hitch point): 147 N (15 kgf, 33 lbf) EBU27571 Loading EWB00820 6 Never exceed the weight limits shown. An overloaded ATV can be unstable. 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. Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ● 6-7 Do not exceed the maximum tongue weight. You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Ad- U1HS10E0.book Page 8 Wednesday, April 13, 2011 10:29 AM ● ● ● ● ● ● ● just the load in the trailer, if necessary, to reduce the weight on the hitch. 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 low range 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. EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 6 6-8 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU21132 RIDING YOUR ATV 7 7-1 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM 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 EBU27399 Get training if you are inexperienced. EWB01381 GETTING TO KNOW YOUR ATV This ATV is mainly for utility use, but may also be used for recreation. 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 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM 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 and cargo 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 U1HS10E0.book Page 4 Wednesday, April 13, 2011 10:29 AM 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 approved 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] 7-4 7 U1HS10E0.book Page 5 Wednesday, April 13, 2011 10:29 AM 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 U1HS10E0.book Page 6 Wednesday, April 13, 2011 10:29 AM ● 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 4-13.) ● ● 1 ● ● ● 1. Adjusting screw ● Loading and accessories Do not exceed the maximum loading limits for the vehicle (see “MAXIMUM LOADING LIMIT” in this section or vehicle labeling). Keep weight on racks centered side to side, and as low as possible. Be sure cargo is secured – a loose load could change handling unexpectedly. Make sure the load does not interfere with your control or ability to see where you are going. Tie down cargo in the trailer securely. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. 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. Take extra precautions when driving with a load or trailer. Follow these instructions and always use common sense and good judgment when carrying cargo or towing a trailer. EWB01462 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: 7-6 7 U1HS10E0.book Page 7 Wednesday, April 13, 2011 10:29 AM 7 During operation Always keep your feet on the footboards 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 footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. [EWB01471] MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 220.0 kg (485 lb) Front carrier: 45.0 kg (99 lb) Rear carrier: 85.0 kg (187 lb) Front storage compartment: 0.5 kg (1 lb) Rear storage compartment: 2.0 kg (4 lb) Trailer hitch: Pulling load (total weight of trailer and cargo): 5880 N (600 kgf, 1322 lbf) Tongue weight (vertical weight on trailer hitch point): 147 N (15 kgf, 33 lbf) Drive 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 to drive slowly (shift into first gear or low drive if available on this model) whenever you are carrying heavier loads or when towing a trailer. Avoid wheelies and jumping. WARNING! Attempting wheelies, jumps, and other stunts increases the chance of an accident, including 7-7 U1HS10E0.book Page 8 Wednesday, April 13, 2011 10:29 AM an overturn. Never attempt stunts, such as wheelies or jumps. Don’t try to show off. Exhaust system EWB01501 [EWB01481] ● ● 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 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] 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. 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 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. 7-8 7 U1HS10E0.book Page 9 Wednesday, April 13, 2011 10:29 AM To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. 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] 7 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 ATVs on public streets, roads and highways. 7-9 U1HS10E0.book Page 10 Wednesday, April 13, 2011 10:29 AM 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 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] 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 careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. [EWB01531] 7-10 U1HS10E0.book Page 11 Wednesday, April 13, 2011 10:29 AM 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 ride in areas posted “no trespassing”. Do not ride on private property without getting permission. 7-11 U1HS10E0.book Page 12 Wednesday, April 13, 2011 10:29 AM 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. Shift to park position 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. With the engine idling, shift the drive select lever into the low-range position or the high-range position. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground, resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. Improper use of the brakes can cause the tires to lose traction, reducing control and increasing the possibility of an accident. ECB00251 NOTICE Do not shift from low-range to high-range or vice versa without coming to a complete stop. Damage to the engine or drive train may occur. 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. 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. 7-12 7 U1HS10E0.book Page 13 Wednesday, April 13, 2011 10:29 AM 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. 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. As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the outside of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even speed through the turn. This maneuver will let the wheel on the inside of the turn slip slightly, allowing the ATV to make the turn properly. 7 CLIMBING UPHILL EWB01671 WARNING Climbing hills improperly can cause overturns or loss of control. Use proper riding techniques described in this Owner’s Manual. 1. Lean towards inside of turn. 2. Support your weight on the outer footboard. 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 7-13 U1HS10E0.book Page 14 Wednesday, April 13, 2011 10:29 AM ● ● ● ● ● ● ● 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. Never open the throttle suddenly. 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 U1HS10E0.book Page 15 Wednesday, April 13, 2011 10:29 AM 7 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. If you start to roll backwards, DO NOT apply either brake abruptly. If you are in “2WD”, apply only the front brake. When fully stopped, apply the rear brake as well, and then shift to the park position. If you are in “4WD”, because all wheels are interconnected by the drive train, applying either brake will brake all wheels, therefore, avoid sudden application of either the front or rear brake as the wheels on the uphill side could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually. When fully stopped, shift to the park position and dismount the ATV immediately on the uphill side. Dismount on uphill side or to a side if pointed straight uphill. Turn 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. For more traction and control for climbing steeper and/or rougher slopes, select “4WD” or 4WD-LOCK (“DIFF. LOCK”). Travel fast enough to maintain momentum, but not so fast that you cannot react to changes in the terrain as you climb. It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars. 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. 7-15 U1HS10E0.book Page 16 Wednesday, April 13, 2011 10:29 AM ● 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] ● ● ● ● ● 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. Apply brakes gradually. If in “2WD”, apply only the rear brake. When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, select the low-range position and change to “4WD” before beginning to descend the hill. RIDING DOWNHILL EWB01621 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. 7-16 7 U1HS10E0.book Page 17 Wednesday, April 13, 2011 10:29 AM 7 Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this ATV is in “4WD”, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the downhill side. Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground. Apply both the front and rear brakes gradually. Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear. 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. ● Avoid crossing the side of a steep hill. 7-17 U1HS10E0.book Page 18 Wednesday, April 13, 2011 10:29 AM ● ● 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. 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 than the depth specified in your Owner’s Manual, as tires may float, increasing the risk of an overturn. 7-18 U1HS10E0.book Page 19 Wednesday, April 13, 2011 10:29 AM ability. WARNING! Wet brakes may have reduced stopping ability, which could cause loss of control. [EWB02621] 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 After riding your ATV in water, be sure to drain the trapped water by removing the check hoses at the bottom of the air filter case. Also, remove the drain plugs from the front and rear storage compartments and the V-belt case to drain any water that may have accumulated. NOTICE: Undrained water can cause damage or improper operation. 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 [ECB00841] Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. 7-19 U1HS10E0.book Page 20 Wednesday, April 13, 2011 10:29 AM 1. Air filter case check hose 1. Storage compartment drain plug 7 1. Air filter case check hose 1. Storage compartment drain plug 7-20 U1HS10E0.book Page 21 Wednesday, April 13, 2011 10:29 AM cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01662 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. 1. V-belt case drain plug 7 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. 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. 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 ac7-21 U1HS10E0.book Page 22 Wednesday, April 13, 2011 10:29 AM 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. 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 U1HS10E0.book Page 23 Wednesday, April 13, 2011 10:29 AM ● WHAT TO DO... If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See 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 IF THE ATV IS IN “2WD” – the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See page 7-13.) ● 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 7-17.) 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 7-18.) EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 7-23 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU2164A PERIODIC MAINTENANCE AND ADJUSTMENT ● EBU21674 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 2-3 for more information about carbon monoxide. EWB02690 WARNING Brake discs, calipers, drums, and linings can become very hot during use. To avoid possible burns, let brake components cool before touching them. 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. The intervals given in the periodic maintenance charts 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. EWB02562 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 8 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. EBU27111 Owner’s manual and tool kit Be sure to put this owner’s manual in the plastic bag and to always carry it as well as the owner’s tool kit and the low-pressure tire gauge in their respective compartments under the seat. TIP If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. 8 1. Owner’s manual 2. Low-pressure tire gauge 3. Owner’s tool kit 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, 8-2 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM 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 * 2 ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 Fuel line • Check fuel hoses for cracks or other damage, and replace if necessary. Spark plug • Check condition and clean, regap, or replace if necessary. √ √ √ EVERY 6 6 12 2500 2500 5000 (1600) (1600) (3200) 160 160 320 √ √ √ √ √ √ √ √ √ 3 * Valves • Check valve clearance and adjust if necessary. 4 * Crankcase breather system • Check breather hose for cracks or other damage, and replace if necessary. √ √ √ 5 * Exhaust system • Check for leakage and replace gasket(s) if necessary. • Check for looseness and tighten all screw clamps and joints if necessary. √ √ √ 8-3 8 U1HS10E0.book Page 4 Wednesday, April 13, 2011 10:29 AM 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 √ √ √ U1HS10E0.book Page 5 Wednesday, April 13, 2011 10:29 AM 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. 1 2 * ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 Air filter element • Clean and replace if necessary. Front brake • Check operation and correct if necessary. • Check fluid level and ATV for fluid leakage, and correct if necessary. • Replace brake pads. EVERY 6 6 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 8-5 12 √ 8 U1HS10E0.book Page 6 Wednesday, April 13, 2011 10:29 AM INITIAL NO. 3 * ITEM Rear brake CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 160 160 320 √ √ √ √ √ • Check operation and correct if necessary. • Check brake pedal free play and adjust if necessary. • Check fluid level and ATV for fluid leakage, and correct if necessary. • Replace brake pads. 4 * Brake hoses 6 6 12 2500 2500 5000 (1600) (1600) (3200) Whenever worn to the limit • Check for cracks or other damage, and replace if necessary. √ • Replace. 8 EVERY √ √ √ √ √ √ Every 4 years 5 * Rear brake hose protectors • Check for wear, cracks or other damage, and replace if necessary. √ 6 * Wheels • Check runout and for damage, and replace if necessary. √ √ √ √ 7 * Tires • Check tread depth and for damage, and replace if necessary. • Check air pressure and balance, and correct if necessary. √ √ √ √ 8 * Wheel hub bearings • Check for looseness or damage, and replace if necessary. √ √ √ √ 9 * V-belt • Check for wear, cracks or other damage, and replace if necessary. √ √ √ √ 8-6 √ U1HS10E0.book Page 7 Wednesday, April 13, 2011 10:29 AM INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first 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) 10 * Chassis fasteners • Make sure that all nuts, bolts, and screws are properly tightened. 11 * Shock absorber assemblies • Check operation and correct if necessary. • Check for oil leakage and replace if necessary. √ √ √ 12 * Stabilizer bushes • Check for cracks or other damage, and replace if necessary. √ √ √ 13 * Rear knuckle pivots • Lubricate with lithium-soap-based grease. √ √ √ 14 * Steering shaft • Lubricate with lithium-soap-based grease. √ √ √ 15 * Steering system • Check operation and repair or replace if damaged. • Check toe-in and adjust if necessary. √ √ √ 16 * Engine mount • Check for cracks or other damage, and replace if necessary. √ √ √ 17 * Axle boots • Check for cracks or other damage, and replace if necessary. √ √ √ √ 18 Engine oil • Change. • Check ATV for oil leakage, and correct if necessary. √ √ √ √ 19 Engine oil filter cartridge • Replace. √ √ 8-7 √ √ √ √ 8 U1HS10E0.book Page 8 Wednesday, April 13, 2011 10:29 AM INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 6 6 12 2500 2500 5000 (1600) (1600) (3200) 160 160 320 20 Differential gear oil • Change. • Check ATV for oil leakage, and correct if necessary. √ √ 21 Final gear oil • Change. • Check ATV for oil leakage, and correct if necessary. √ √ 22 Cooling system • Check coolant level and ATV for coolant leakage, and correct if necessary. √ √ • Replace coolant. 8 EVERY √ √ √ √ √ √ √ √ √ Every 2 years 23 * Moving parts and cables • Lubricate. 24 * Drive select lever safety system cable • Check operation and adjust or replace if necessary. 25 * Throttle lever • Check operation. • Check throttle lever free play, and adjust if necessary. • Lubricate cable and lever housing. √ √ √ √ √ 26 * Front and rear brake switches • Check operation and correct if necessary. √ √ √ √ √ 27 * Lights and switches • Check operation and correct if necessary. • Adjust headlight beams. √ √ √ √ √ √ 8-8 U1HS10E0.book Page 9 Wednesday, April 13, 2011 10:29 AM EBU23071 TIP ● Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● 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 8-9 U1HS10E0.book Page 10 Wednesday, April 13, 2011 10:29 AM EWB00011 3 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 1 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. 2 1 3 2 4 1. Panel E 2. Panel G 3. Panel H EBU27385 8 Panel A To remove the panel Pull upward on the areas shown. 5 1. 2. 3. 4. 5. Panel A Panel B Panel C Panel D Panel F 8-10 U1HS10E0.book Page 11 Wednesday, April 13, 2011 10:29 AM Panel B To remove the panel 1. Remove panel A. 2. Remove the front carrier by removing the bolts. 1. Panel A To install the panel Place the panel in the original position. 8 1. Carrier bolt (under the fenders) 8-11 U1HS10E0.book Page 12 Wednesday, April 13, 2011 10:29 AM 1. Front carrier 2. Carrier bolt (top) 1. Front carrier stay 3. Remove the front carrier stays by removing the bolts. 8 1. Front carrier stay bolt 4. Remove the quick fasteners, and then pull the panel upward to remove it. 8-12 U1HS10E0.book Page 13 Wednesday, April 13, 2011 10:29 AM 1. Panel B 2. Quick fastener 2. Install the front carrier stays by installing the bolts and tightening them to the specified torque. To install the panel 1. Place the panel in the original position, and then install the quick fasteners. Tightening torque: Front carrier stay bolt: 34 Nm (3.4 m·kgf, 25 ft·lbf) 3. Install the front carrier by installing the bolts and tightening them to the specified torques. 8-13 8 U1HS10E0.book Page 14 Wednesday, April 13, 2011 10:29 AM To install the panel 1. Place the panel in the original position, and then install the quick fastener screws. Tightening torques: Carrier bolt (top): 34 Nm (3.4 m·kgf, 25 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 4. Install panel A. Panel C To remove the panel 1. Remove the seat. (See page 4-18.) 2. Remove the quick fastener screws, and then pull the panel upward to remove it. 2. Install the seat. 8 Panels D and E To remove a panel 1. Remove panels A and C. 2. Remove the quick fastener screw and bolt, and then pull the panel upward to remove it. TIP To ease removal of panel D, shift the drive select lever into the reverse position. 1. Panel C 2. Quick fastener screw 8-14 U1HS10E0.book Page 15 Wednesday, April 13, 2011 10:29 AM 1. Panel D 2. Quick fastener screw 1. Panel E 2. Quick fastener screw 8 1. Bolt 1. Bolt 8-15 U1HS10E0.book Page 16 Wednesday, April 13, 2011 10:29 AM To install a panel 1. Place the panel in the original position, and then install the bolt and quick fastener screw. Panels F and G To remove a panel 1. Remove the panel bolts, footboard bolt, and footboard nut. 2. Pull the panel downward while pushing the projection. 8 1. 2. 3. 4. 5. 2. Install panels A and C. 8-16 Panel F Footboard nut Footboard bolt Panel bolt Projection U1HS10E0.book Page 17 Wednesday, April 13, 2011 10:29 AM 1. 2. 3. 4. 5. Panel G Footboard nut Footboard bolt Panel bolt Projection 8 To install a panel 1. Place the panel in the original position. 2. Install the bolts and nut, and then tighten them to the specified torques. 8-17 U1HS10E0.book Page 18 Wednesday, April 13, 2011 10:29 AM Tightening torques: Panel bolt: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Footboard nut: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Panel H To remove the panel 1. Remove the seat. (See page 4-18.) 2. Remove the rear carrier by removing the bolts. 1. Rear carrier 2. Carrier bolt (upper) 8 1. Carrier bolt (under the fenders) 1. Carrier bolt (lower) 8-18 U1HS10E0.book Page 19 Wednesday, April 13, 2011 10:29 AM 3. Remove the quick fasteners, and then push inward on the areas shown. 2 1 2. Install the rear carrier by installing the bolts and tightening them to the specified torques. 1. Panel H 2. Quick fastener Tightening torques: Carrier bolt (upper): 53 Nm (5.3 m·kgf, 38 ft·lbf) Carrier bolt (lower): 53 Nm (5.3 m·kgf, 38 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) To install the panel 1. Place the panel in the original position, and then install the quick fasteners. 3. Install the seat. 8-19 8 U1HS10E0.book Page 20 Wednesday, April 13, 2011 10:29 AM EBU28671 EBU23213 Removing the radiator grills Checking the spark plug The radiator grills can be removed to access the radiator for cleaning. The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine. To remove a radiator grill Remove the quick fastener, pull the radiator grill outward at the top, and then pull it upward. 2 To remove the spark plug 1. Remove the spark plug cap. 1 8 1 1. Radiator grill 2. Quick fastener To install a radiator grill Place the radiator grill in its original position, and then install the quick fastener. 1. Spark plug cap 8-20 U1HS10E0.book Page 21 Wednesday, April 13, 2011 10:29 AM 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. TIP 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 ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/LMAR6A-9 3. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 1. Spark plug wrench To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the ATV is ridden normally). 8-21 8 U1HS10E0.book Page 22 Wednesday, April 13, 2011 10:29 AM Tightening torque: Spark plug: 13 Nm (1.3 m·kgf, 9.4 ft·lbf) 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. 1. Spark plug gap 3. Install the spark plug cap. Spark plug gap: 0.8–0.9 mm (0.031–0.035 in) EBU27467 Engine oil and oil filter cartridge 8 The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. To install the spark plug 1. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 2. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. To check the engine oil level 1. Place the ATV on a level surface. 2. Check the engine oil level on a cold engine. 8-22 U1HS10E0.book Page 23 Wednesday, April 13, 2011 10:29 AM TIP If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least 10 minutes until the oil settles for an accurate reading. 3. Remove the access cover by turning it counterclockwise. 1. Engine oil dipstick 5. Insert the dipstick completely into the oil filler hole, and then remove it again to check the oil level. TIP The engine oil should be between the minimum and maximum level marks. 1. Access cover 4. Remove the engine oil dipstick, and then wipe it off with a clean rag. 8-23 8 U1HS10E0.book Page 24 Wednesday, April 13, 2011 10:29 AM To change the engine oil (with or without oil filter cartridge replacement) 1. Place the ATV on a level surface. 2. Remove the access cover by turning it counterclockwise. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the dipstick, and then remove the engine oil drain bolt and its gasket to drain the oil from the crankcase. 2 1. Maximum level mark 2. Minimum level mark 8 6. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. NOTICE: Be sure the engine oil is at the correct level, otherwise engine damage may result. [ECB00851] 7. Insert the dipstick completely into the oil filler hole. 8. Install the access cover by turning it clockwise. 1 1. Engine oil drain bolt 2. Gasket 8-24 U1HS10E0.book Page 25 Wednesday, April 13, 2011 10:29 AM TIP Skip steps 5–9 if the oil filter cartridge is not being replaced. 5. Remove panel F. (See page 8-10.) 6. Remove the oil filter cartridge with an oil filter wrench. 1. O-ring TIP Make sure that the O-ring is properly seated. 8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 1. Oil filter cartridge 2. Oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer. 7. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 8-25 8 U1HS10E0.book Page 26 Wednesday, April 13, 2011 10:29 AM 11. Refill with the specified amount of the recommended engine oil, and then insert the dipstick completely into the oil filler hole. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.00 L (2.11 US qt, 1.76 Imp.qt) With oil filter cartridge replacement: 2.10 L (2.22 US qt, 1.85 Imp.qt) 1. Torque wrench 8 TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) ECB00300 9. Install panel F. 10. Install the engine oil drain bolt and its new gasket, and then tighten the bolt to the specified torque. 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. ● Tightening torque: Engine oil drain bolt: 30 Nm (3.0 m·kgf, 22 ft·lbf) 8-26 U1HS10E0.book Page 27 Wednesday, April 13, 2011 10:29 AM ● 2. Remove the final gear oil level check bolt and its gasket, and then check the oil level in the final gear case. The oil level should be at the brim of the check hole. Make sure that no foreign material enters the crankcase. 12. 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. 13. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. 14. Install the access cover by turning it clockwise. 1 2 3 4 EBU27306 Final gear oil The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. 2. 3. 4. Final gear oil Gasket Final gear oil level check bolt Correct oil level 3. If the oil is below the brim of the check hole, remove the final gear oil filler bolt and its gasket, and then add sufficient oil of the recommended type to raise it to the correct level. To check the final gear oil level 1. Place the ATV on a level surface. 8-27 8 U1HS10E0.book Page 28 Wednesday, April 13, 2011 10:29 AM To change the final gear oil 1. Place the ATV on a level surface. 2. Place an oil pan under the final gear case to collect the used oil. 3. Remove the final gear oil filler bolt, the final gear oil level check bolt, the final gear oil drain bolt and their gasket to drain the oil from the final gear case. 2 1 1. Final gear oil filler bolt 2. Gasket 8 4. Check the gaskets for damage, and replace them if necessary. 5. Install the oil level check bolt, the oil filler bolt and their gasket, and then tighten the bolts to the specified torques. 2 1 1. Final gear oil drain bolt 2. Gasket Tightening torques: Final gear oil level check bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 4. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque. 8-28 U1HS10E0.book Page 29 Wednesday, April 13, 2011 10:29 AM 6. Check the oil level check bolt gasket and the oil filler bolt gasket for damage, and replace them if necessary. 7. Install the oil level check bolt, the oil filler bolt and their gasket, and then tighten the bolts to the specified torques. Tightening torque: Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 5. Refill with the recommended final gear oil to the brim of the check hole as shown. NOTICE: Be sure no foreign material enters the final gear case. [ECB00421] 1 Tightening torques: Final gear oil level check bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 2 3 8. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 4 EBU23426 Differential gear oil 1. 2. 3. 4. The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. Final gear oil Gasket Final gear oil level check bolt Correct oil level Recommended final gear oil: See page 10-1. 8-29 8 U1HS10E0.book Page 30 Wednesday, April 13, 2011 10:29 AM 5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque. To check the differential gear oil level 1. Place the ATV on a level surface. 2. Remove the differential gear oil filler bolt and its gasket, and then check the oil level in the differential gear case. The oil level should be at the brim of the filler hole. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) To change the differential gear oil 1. Place the ATV on a level surface. 2. Place an oil pan under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt, the differential gear oil drain bolt and their gasket to drain the oil from the differential gear case. 1 2 3 8 4 1. 2. 3. 4. Differential gear oil filler bolt Gasket Differential gear oil Correct oil level 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 4. Check the gasket for damage, and replace it if necessary. 8-30 U1HS10E0.book Page 31 Wednesday, April 13, 2011 10:29 AM 1 2 2 3 1 4 1. Differential gear oil drain bolt 2. Gasket 1. 2. 3. 4. 4. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque. Differential gear oil filler bolt Gasket Differential gear oil Correct oil level Recommended differential gear oil: See page 10-1. Tightening torque: Differential gear oil drain bolt: 9.8 Nm (0.98 m·kgf, 7.1 ft·lbf) 6. Check the oil filler bolt gasket for damage, and replace it if necessary. 7. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque. 5. Refill with the recommended differential gear oil to the brim of the filler hole as shown. NOTICE: Be sure no foreign material enters the differential gear case. [ECB00411] Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 8-31 8 U1HS10E0.book Page 32 Wednesday, April 13, 2011 10:29 AM 8. Check the differential gear case for oil leakage. If oil is leaking, check for the cause. EBU23470 Coolant 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. EBU27126 To check the coolant level 1. Place the ATV on a level surface. 8 1. Maximum level mark 2. Minimum level mark TIP The coolant level must be checked on a cold engine since the level varies with engine temperature. 3. If the coolant is at or below the minimum level mark, remove panel D to access the coolant reservoir. (See page 8-10.) 4. Remove the coolant reservoir cap, add coolant or distilled water to the maximum level mark, install the reservoir cap, and then install the panel. 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 2. Check the coolant level in the coolant reservoir. TIP The coolant should be between the minimum and maximum level marks. 8-32 U1HS10E0.book Page 33 Wednesday, April 13, 2011 10:29 AM 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] TIP ● The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. ● If the engine overheats, see page 8-68 for further instructions. EBU27766 To change the coolant EWB01890 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 place a thick rag over the cap when opening. Allow any remaining pressure to escape before completely removing the cap. 1. Coolant reservoir cap 2. Maximum level mark 3. Minimum level mark 1. Place the ATV on a level surface. 2. Remove panel D. (See page 8-10.) 3. Remove the footboard by removing the bolts and nuts. Coolant reservoir capacity (up to the maximum level mark): 0.24 L (0.25 US qt, 0.21 Imp.qt) 8-33 8 U1HS10E0.book Page 34 Wednesday, April 13, 2011 10:29 AM 1 2 3 3 2 2 1 1. Footboard 2. Bolt and nut 3. Bolt 8 1. Coolant drain bolt 2. Gasket 4. Place a container under the engine, and then remove the coolant drain bolt and its gasket. (Use a trough or a similar object as shown to prevent coolant from spilling on the engine guard.) 1 1. Trough 5. Remove panel B. (See page 8-10.) 8-34 U1HS10E0.book Page 35 Wednesday, April 13, 2011 10:29 AM 6. Remove the radiator cap. 1. Coolant reservoir hose 1. Radiator cap 9. After draining the coolant, thoroughly flush the cooling system with clean tap water. 10. Install the coolant drain bolt and its new gasket, and then tighten the bolt to the specified torque. 7. Remove the coolant reservoir cap. 8. Disconnect the coolant reservoir hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. Tightening torque: Coolant drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 11. Connect the coolant reservoir hose. 12. Pour the recommended coolant into the radiator until it is full. 8-35 8 U1HS10E0.book Page 36 Wednesday, April 13, 2011 10:29 AM 13. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap. NOTICE: Mix antifreeze with distilled water only. However, if distilled water is not available, soft water may be used for refilling. Do not use hard water or salt water since they are harmful to the engine. [ECB00991] 8 1 Antifreeze/water mixture ratio: 1:1 Recommended antifreeze: High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Coolant quantity: Radiator capacity (including all routes): 1.99 L (2.10 US qt, 1.75 Imp.qt) Coolant reservoir capacity (up to the maximum level mark): 0.24 L (0.25 US qt, 0.21 Imp.qt) 1. Water pump air bleed bolt 15. When coolant begins to flow out of the bolt hole, tighten the water pump air bleed bolt to the specified torque. Tightening torque: Water pump air bleed bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 16. Remove panel E. (See page 8-10.) 17. Loosen the clamp screw, and then remove the V-belt cooling duct. 14. Loosen the water pump air bleed bolt, without removing it, to allow all of the air to escape from the air bleed bolt hole. 8-36 U1HS10E0.book Page 37 Wednesday, April 13, 2011 10:29 AM 1. V-belt cooling duct 2. Clamp screw 1. Cylinder head air bleed bolt 19. When coolant begins to flow out of the bolt hole, tighten the cylinder head air bleed bolt to the specified torque. 18. Loosen the cylinder head air bleed bolt, without removing it, to allow all of the air to escape from the air bleed bolt hole. Tightening torque: Cylinder head air bleed bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 20. Start the engine and let it idle for ten minutes. 21. Rev the engine five times. 22. Pour the recommended coolant into the radiator until it is full. 8-37 8 U1HS10E0.book Page 38 Wednesday, April 13, 2011 10:29 AM 23. Stop the engine and allow it to cool. If the coolant level has dropped after the engine has cooled, add sufficient coolant until it reaches the top of the radiator, and then install the radiator cap. 24. Start the engine, and then check for coolant leakage. 2 3 1 TIP If any leakage is found, have a Yamaha dealer check the cooling system. 8 1. Footboard nut 2. Footboard bolt A 3. Footboard bolt B 25. Install the V-belt cooling duct, and then tighten the clamp screw. 26. Install the footboard by installing the bolts and nuts, and then tighten them to the specified torques. Tightening torques: Footboard nut: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Footboard bolt A: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Footboard bolt B: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 27. Install the panels. 8-38 1 U1HS10E0.book Page 39 Wednesday, April 13, 2011 10:29 AM EBU27806 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 are two check hoses at the bottom of the air filter case, which are located behind panels D and E. (See page 8-10 for an explanation on removing the panels.) Check the hoses periodically and, if dust or water collects in them, empty them and clean the air filter element and air filter case. 1. Air filter case check hose 8 1. Air filter case check hose 1. Place the ATV on a level surface. 2. Remove panel C. (See page 8-10.) 8-39 U1HS10E0.book Page 40 Wednesday, April 13, 2011 10:29 AM 3. Remove the air filter case cover by unhooking the holders. 1. Air filter case cover holder 2. Air filter case cover 8 4. Remove the sponge material and the air filter mesh from the air filter case. 1. Sponge material 2. Air filter mesh 5. Clean the mesh with solvent, and then wipe the solvent off. 8-40 U1HS10E0.book Page 41 Wednesday, April 13, 2011 10:29 AM 6. 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] 7. 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. 10. Install the mesh and the sponge material into the air filter case. 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] 11. Insert the projections on the air filter case cover into the holders on the air filter case, and then install the air filter case cover by hooking the holders onto the cover. [ECB00441] 8. Check the sponge material and replace it if damaged. 9. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material. 8-41 8 U1HS10E0.book Page 42 Wednesday, April 13, 2011 10:29 AM 13. Install the panel. 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. Air filter case cover 12. Place the hoses in their original position as shown. EBU27813 Cleaning the spark arrester 8 Select a well-ventilated area free of combustible materials and make sure the exhaust and muffler are cool. 1. Remove the tailpipe bolts. 1 1. Hose 8-42 U1HS10E0.book Page 43 Wednesday, April 13, 2011 10:29 AM 1. Tailpipe bolt 1. Tailpipe 2. Spark arrester 3. Gasket 2. Remove the tailpipe by pulling it out of the muffler, and then remove the gasket. 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. 4. Check the gasket for damage, and replace it if necessary. 5. Install the gasket, and then insert the tailpipe into the muffler and align the bolt holes. 6. Install the bolts and tighten them to the specified torque. Tightening torque: Tailpipe bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 7. Remove the purging bolt and its gasket. 8-43 8 U1HS10E0.book Page 44 Wednesday, April 13, 2011 10:29 AM Tightening torque: Purging bolt: 27 Nm (2.7 m·kgf, 20 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. 2 1. Purging bolt 2. Gasket 8 8. 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. 9. Stop the engine and allow the exhaust pipe to cool. 10. Check the gasket for damage, and replace it if necessary. 11. Install the purging bolt and its gasket, and then tighten the bolt to the specified torque. EBU23931 V-belt case drain plug After riding in water deep enough to allow it to enter the V-belt case, remove the V-belt case drain plug to drain the water from the case. 8-44 U1HS10E0.book Page 45 Wednesday, April 13, 2011 10:29 AM 1. Slide the rubber cover back. 2. Loosen the locknut. 3. To increase the throttle lever free play, turn the throttle lever free play adjusting bolt in direction (a). To decrease the throttle lever free play, turn the adjusting bolt in direction (b). TIP If water drains from the V-belt case after removing the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts. 1 (b) 2 3 (a) 2WD 4WD 4 1. V-belt case drain plug 1. 2. 3. 4. EBU29702 Adjusting the throttle lever free play The throttle lever free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The throttle lever free play should measure 3.0– 5.0 mm (0.12–0.20 in) as shown. Periodically check the throttle lever free play and, if necessary, adjust it as follows. Rubber cover Throttle lever free play adjusting bolt Locknut Throttle lever free play 4. Tighten the locknut. 5. Slide the rubber cover to its original position. 8-45 8 U1HS10E0.book Page 46 Wednesday, April 13, 2011 10:29 AM EBU24060 EWB02571 Valve clearance WARNING Operating with improperly serviced or adjusted brakes could lead to a loss in braking ability and an accident. 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. EBU27470 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. EBU24071 Adjusting the drive select lever safety system cable 8 The drive select lever safety system cable stretches with use, which can result in improper function. Therefore, the safety system cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. TIP The wheels need to be removed to check the brake pads. (See page 8-64.) EBU29601 Brakes Replacement of brake components requires professional knowledge. Brake service should be performed by a Yamaha dealer. 8-46 U1HS10E0.book Page 47 Wednesday, April 13, 2011 10:29 AM Front brake EBU27843 Checking the rear brake hose protectors The rear brake hose protectors must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake hose protector is provided with a wear indicator. If a protector wears to the point that its indicator becomes visible, have a Yamaha dealer replace the protector. TIP The wheels need to be removed to check the brake hose protectors. (See page 8-64.) 1. Wear indicator groove Rear brake 8 1. Wear indicator groove 8-47 U1HS10E0.book Page 48 Wednesday, April 13, 2011 10:29 AM Front brake 2WD 4WD 1 1. 2. 3. 4. 8 Rear brake hose protector Wear indicator Protector is normal. Protector is worn. 1. Minimum level mark Rear brake EBU29841 Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid level with the top of the reservoir level. Replenish the brake fluid if necessary. 1. Minimum level mark 8-48 U1HS10E0.book Page 49 Wednesday, April 13, 2011 10:29 AM ECB01160 Specified brake fluid: DOT 4 NOTICE Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled fluid immediately. EWB02720 WARNING Improper maintenance can result in loss of braking ability. Observe these precautions: ● Insufficient brake fluid may allow air to enter the brake system, reducing braking performance. ● Clean the filler cap before removing. Use only DOT 4 brake fluid from a sealed container. ● Use only the specified brake fluid; otherwise, the rubber seals may deteriorate, causing leakage. ● Refill with the same type of brake fluid. Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction. ● 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. As the brake pads wear, it is normal for the brake fluid level to gradually go down. A low brake fluid level may indicate worn brake pads and/or brake system leakage; therefore, be sure to check the brake pads for wear and the brake system for leakage. If the brake fluid level goes down suddenly, have a Yamaha dealer check the cause before further riding. 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. 8-49 8 U1HS10E0.book Page 50 Wednesday, April 13, 2011 10:29 AM Rear brake EBU27772 Checking the front and rear brake lever free play The front and rear brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake levers should have no free play as shown. If there is free play, have a Yamaha dealer check the brake system. Front brake 1. No brake lever free play EBU29072 Adjusting the brake pedal free play 8 The brake pedal free play must be adjusted at the intervals specified in the periodic maintenance and lubrication chart. TIP Always perform this maintenance completely in the following order whenever adjusting the rear brake. ● Before adjusting the brake pedal free play, check the rear brake pads for wear. ● 1. No brake lever free play 8-50 U1HS10E0.book Page 51 Wednesday, April 13, 2011 10:29 AM The brake pedal free play should measure 1.0–6.0 mm (0.04–0.24 in) as shown. If the free play is incorrect, adjust it as follows. 1. Locknut 2. Brake pedal free play adjusting nut 4. Tighten the locknut. 5. After adjusting, there should be slight play at the brake pedal cable joint as shown. If there is no play, repeat steps 2 to 4. 1. Brake pedal free play 1. Remove panel G. (See page 8-10.) 2. Loosen the locknut. 3. Turn the brake pedal free play adjusting nut in direction (a) to increase the free play, and in direction (b) to decrease it. 8-51 8 U1HS10E0.book Page 52 Wednesday, April 13, 2011 10:29 AM EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart. Check the axle boots for tears or damage. If any damage is found, have them replaced by a Yamaha dealer. 1 2 1. Brake pedal cable joint 2. Slight play (0.1–0.5 mm [0.004–0.02 in]) 8 6. Install the panel. If the correct free play cannot be obtained, have a Yamaha dealer adjust it. 1 TIP When adjusting the rear brake pedal free play: ● Be sure not to step on the brake pedal. ● Make sure the rear brake lever and brake pedal do not move. 1. Front axle boot (each side) 8-52 1 U1HS10E0.book Page 53 Wednesday, April 13, 2011 10:29 AM EWB02581 ● ● 1 1 1. Rear axle boot (each side) EBU24902 Checking and lubricating the cables 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. 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. EBU24912 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Recommended lubricant: Yamaha Chain and Cable Lube or engine oil Recommended lubricant: Silicone grease 8-53 8 U1HS10E0.book Page 54 Wednesday, April 13, 2011 10:29 AM Front brake lever EBU28832 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. TIP To access the brake pedal pivot, remove panel G. (See page 8-10.) Recommended lubricant: Lithium-soap-based grease Rear brake lever 8 8-54 U1HS10E0.book Page 55 Wednesday, April 13, 2011 10:29 AM EBU24963 EBU25052 Checking the wheel hub bearings Lubricating the rear knuckle pivots 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. The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. TIP For parts equipped with a grease nipple, use a grease gun. Recommended lubricant: Lithium-soap-based grease 8 EBU25022 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bushes if necessary. 1. Grease nipple 8-55 U1HS10E0.book Page 56 Wednesday, April 13, 2011 10:29 AM EBU25092 EWB02160 Lubricating the steering shaft 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. The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. TIP For parts equipped with a grease nipple, use a grease gun. Recommended lubricant: Lithium-soap-based grease EBU2904A Battery 8 The battery is located under panel A. (See page 8-10.) 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. 8-56 U1HS10E0.book Page 57 Wednesday, April 13, 2011 10:29 AM To remove the battery 1. Remove panel A. (See page 8-10.) 2. Remove the front carrier by removing the bolts. 1. Front carrier 2. Carrier bolt (top) 3. Remove the battery holding plate by removing the nuts. 4. 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] 1. Carrier bolt (under the fenders) 8-57 8 U1HS10E0.book Page 58 Wednesday, April 13, 2011 10:29 AM ECB00931 1 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. 4 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. 2 3 1. 2. 3. 4. 8 Battery holding plate Nut Negative battery lead (black) Positive battery lead (red) ECB00940 NOTICE Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. 5. Pull the battery out of its compartment. 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. To install the battery TIP Be sure the battery is fully charged. 1. Place the battery in its compartment. 8-58 U1HS10E0.book Page 59 Wednesday, April 13, 2011 10:29 AM 2. Connect the positive battery lead first, then connect the negative battery lead by installing their bolt. NOTICE: When installing the battery, the main switch must be off, and the positive lead must be connected before the negative lead. [ECB01110] Tightening torques: Carrier bolt (top): 34 Nm (3.4 m·kgf, 25 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 5. Install the panel. 1 EBU30520 Replacing a fuse 8 2 1. Positive battery lead (red) 2. Negative battery lead (black) 3. Install the battery holding plate by installing the nuts. 4. Install the front carrier by installing the bolts and tightening them to the specified torques. 1. 2. 3. 4. 5. 8-59 Fuse box Main fuse EPS fuse (for EPS model) Fuel injection system spare fuse Fuel injection system fuse U1HS10E0.book Page 60 Wednesday, April 13, 2011 10:29 AM ECB00640 NOTICE To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 8 1. 2. 3. 4. 5. 6. 7. 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] Auxiliary DC jack fuse Four-wheel-drive motor fuse Ignition fuse Radiator fan fuse Signaling system fuse Headlight fuse Spare fuse The main fuse, the fuel injection system fuse, the EPS fuse, and the fuse box are located under panel A. (See page 8-10.) If a fuse is blown, replace it as follows. 1. Turn the key to “ ” (off) and turn off all electrical circuits. 8-60 U1HS10E0.book Page 61 Wednesday, April 13, 2011 10:29 AM EBU27443 Specified fuses: Main fuse: 40.0 A Headlight fuse: 10.0 A Ignition fuse: 10.0 A Four-wheel-drive motor fuse: 10.0 A Signaling system fuse: 5.0 A Auxiliary DC jack fuse: 10.0 A Radiator fan fuse: 20.0 A Fuel injection system fuse: 15.0 A EPS fuse: YFM5FGPB 40.0 A YFM5FGPHB 40.0 A Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 1. Cover at the rear of the headlight 2. Remove the headlight bulb cover. 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. 8-61 8 U1HS10E0.book Page 62 Wednesday, April 13, 2011 10:29 AM 4. Unhook the headlight bulb holder, and then remove the burnt-out bulb. 1. Headlight bulb cover 3. Disconnect the headlight coupler. 1. Headlight bulb holder 2. Headlight bulb 8 5. Place a new headlight bulb into position, and then secure it with the bulb holder. 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] 1. Headlight coupler 8-62 U1HS10E0.book Page 63 Wednesday, April 13, 2011 10:29 AM To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b). 1. Do not touch the glass part of the bulb. 6. Connect the headlight coupler. 7. Install the headlight bulb cover. NOTICE: Make sure the headlight bulb cover is securely fitted and seated properly. [ECB01080] 8. Install the cover at the rear of the headlight. 9. Adjust the headlight beam if necessary. 1. Headlight beam adjusting screw EBU25642 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Remove panel H. (See page 8-10.) 2. Remove the tail/brake light bulb holder (together with the bulb) by turning it counterclockwise. EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. 8-63 8 U1HS10E0.book Page 64 Wednesday, April 13, 2011 10:29 AM 4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the panel. EBU25651 Removing a wheel 1. Place the ATV on a level surface. 2. Loosen the wheel nuts. 1. Tail/brake light bulb holder 3. Remove the burnt-out bulb by pushing it in and turning it counterclockwise. 8 1. Wheel nut 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. 1. Tail/brake light bulb 8-64 U1HS10E0.book Page 65 Wednesday, April 13, 2011 10:29 AM EBU25701 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts. TIP ● The arrow mark on the tire must point toward the rotating direction of the wheel. ● Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Tapered nut 1 3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified torques. Tightening torques: Front wheel nut: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear wheel nut: 55 Nm (5.5 m·kgf, 40 ft·lbf) 1. Arrow mark 8-65 8 U1HS10E0.book Page 66 Wednesday, April 13, 2011 10:29 AM EBU25740 Troubleshooting 8 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. 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. 8-66 U1HS10E0.book Page 67 Wednesday, April 13, 2011 10:29 AM EBU27693 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 have a Yamaha dealer charge the battery if necessary. Operate the electric starter. 8-67 The engine does not start. Have a Yamaha dealer check the ATV. U1HS10E0.book Page 68 Wednesday, April 13, 2011 10:29 AM 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. 8-68 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU25860 CLEANING AND STORAGE EBU25881 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 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 may cause water seepage and deteriora- 4. 5. 6. 7. 9-1 tion 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. 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 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM 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 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM 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 8-56. TIP Make any necessary repairs before storing the ATV. 9 9-3 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU25961 SPECIFICATIONS Dimensions: Compression ratio: 9.30 : 1 Starting system: Electric starter Lubrication system: Wet sump Overall length: 2065 mm (81.3 in) Overall width: 1180 mm (46.5 in) Overall height: 1240 mm (48.8 in) Seat height: 905 mm (35.6 in) Wheelbase: 1250 mm (49.2 in) Ground clearance: 275 mm (10.8 in) Minimum turning radius: 3200 mm (126 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: 294.0 kg (648 lb) SAE 10W-30 Engine: 10 50 SAE 10W-40 Engine type: Liquid cooled 4-stroke, SOHC Cylinder arrangement: Forward-inclined single cylinder Displacement: 558 cm³ Bore × stroke: 92.0 × 84.0 mm (3.62 × 3.31 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 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM Fuel injection: Engine oil quantity: Without oil filter cartridge replacement: 2.00 L (2.11 US qt, 1.76 Imp.qt) With oil filter cartridge replacement: 2.10 L (2.22 US qt, 1.85 Imp.qt) Throttle body: ID mark: 28P7 10 Spark plug (s): Final gear oil: Manufacturer/model: NGK/LMAR6A-9 Spark plug gap: 0.8–0.9 mm (0.031–0.035 in) Type: SAE 80 API GL-4 Hypoid gear oil Quantity: 0.20 L (0.21 US qt, 0.18 Imp.qt) Clutch: Differential gear oil: Clutch type: Wet, centrifugal automatic Type: SAE 80 API GL-4 Hypoid gear oil Quantity: 0.22 L (0.23 US qt, 0.19 Imp.qt) Transmission: Primary reduction system: V-belt Secondary reduction system: Shaft drive Secondary reduction ratio: 41/21 × 24/18 × 33/9 (9.544) Transmission type: V-belt automatic Operation: Left hand operation Reverse gear: 23/14 × 28/23 (2.000) Low range: 31/16 (1.938) High range: 31/27 (1.148) Cooling system: Coolant reservoir capacity (up to the maximum level mark): 0.24 L (0.25 US qt, 0.21 Imp.qt) Radiator capacity (including all routes): 1.99 L (2.10 US qt, 1.75 Imp.qt) Air filter: Air filter element: Wet element Fuel: Recommended fuel: Unleaded gasoline only Fuel tank capacity: 20.0 L (5.28 US gal, 4.40 Imp.gal) Fuel reserve amount: 4.5 L (1.19 US gal, 0.99 Imp.gal) 10-2 10 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM Chassis: Minimum: Front: 32.0 kPa (0.320 kgf/cm², 4.6 psi) Rear: 27.0 kPa (0.270 kgf/cm², 4.0 psi) Frame type: Steel tube frame Caster angle: 5.0 ° Trail: 26.0 mm (1.02 in) Front wheel: Wheel type: Panel wheel Rim size: 12 x 6.0 AT Front tire: Type: Tubeless Size: AT25 x 8-12 Manufacturer/model: MAXXIS/MU19 Rear wheel: Wheel type: Panel wheel Rim size: 12 x 7.5 AT Rear tire: Front brake: Type: Tubeless Size: AT25 x 10-12 Manufacturer/model: MAXXIS/MU20 Type: Disc brake Operation: Right hand operation Specified brake fluid: DOT 4 Loading: 10 Rear brake: Maximum loading limit: 220.0 kg (485 lb) (Total weight of rider, cargo, accessories, and tongue) Type: Disc brake Operation: Left hand and right foot operation Specified brake fluid: DOT 4 Tire air pressure (measured on cold tires): Recommended: Front: 35.0 kPa (0.350 kgf/cm², 5.0 psi) Rear: 30.0 kPa (0.300 kgf/cm², 4.4 psi) 10-3 U1HS10E0.book Page 4 Wednesday, April 13, 2011 10:29 AM Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Meter lighting: EL (Electroluminescent) Neutral indicator light: LED Reverse indicator light: LED Coolant temperature warning light: LED Engine trouble warning light: LED EPS warning light: YFM5FGPB LED YFM5FGPHB LED Park indicator light: LED On-Command four-wheel-drive/differential gear lock indicator: LCD High-range indicator light: LED Low-range indicator light: LED Differential gear lock indicator light: LED Type: Double wishbone Spring/shock absorber type: Coil spring/oil damper Wheel travel: 180 mm (7.1 in) Rear suspension: Type: Double wishbone Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 230 mm (9.1 in) Electrical system: Ignition system: TCI Charging system: AC magneto Battery: Model: YTX20L-BS Voltage, capacity: 12 V, 18.0 Ah Headlight: Bulb type: Halogen bulb Fuses: Main fuse: 40.0 A Fuel injection system fuse: 15.0 A Bulb voltage, wattage × quantity: Headlight: 12 V, 35.0/35.0 W × 2 10-4 10 U1HS10E0.book Page 5 Wednesday, April 13, 2011 10:29 AM EPS fuse: YFM5FGPB 40.0 A YFM5FGPHB 40.0 A Headlight fuse: 10.0 A Signaling system fuse: 5.0 A Ignition fuse: 10.0 A Auxiliary DC jack fuse: 10.0 A Four-wheel-drive motor fuse: 10.0 A Radiator fan fuse: 20.0 A 10 10-5 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU25981 CONSUMER INFORMATION EBU26013 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 EBU26030 MODEL LABEL INFORMATION: Vehicle identification number The vehicle identification number is stamped into the frame. 11-1 11 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM 1. Vehicle identification number (front left side) 1. Model label TIP The vehicle identification number is used to identify your ATV. EBU29662 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 11 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. 11-2 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM 1 1. Vehicle Emission Control Information label 11 11-3 U1HS10E0.book Page 4 Wednesday, April 13, 2011 10:29 AM 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 U1HS10E0.book Page 5 Wednesday, April 13, 2011 10:29 AM 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 SERVICING DEALER NAME AND ADDRESS REMARKS 11 11-5 U1HS10E0.book Page 6 Wednesday, April 13, 2011 10:29 AM 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 11 11-6 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 U1HS10E0.book Page 7 Wednesday, April 13, 2011 10:29 AM 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. 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 11 U1HS10E0.book Page 8 Wednesday, April 13, 2011 10:29 AM EBU26124 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 $250 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. 11 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. 11-8 U1HS10E0.book Page 9 Wednesday, April 13, 2011 10:29 AM 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 U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM INDEX A Accessories and loading ................................................ 6-6 Accessories, auxiliary jack ........................................... 4-23 Air filter element, cleaning ............................................ 8-39 Axle boots .................................................................... 8-52 Drive select lever .......................................................... 4-15 Drive select lever and driving in reverse ........................ 6-2 Drive select lever safety system cable, adjusting ......... 8-46 E Engine break-in .............................................................. 6-4 Engine oil ....................................................................... 5-3 Engine oil and oil filter cartridge ................................... 8-22 Engine stop switch ......................................................... 4-7 Engine trouble warning light ........................................... 4-3 EPS warning light (for EPS model) ................................ 4-3 B Battery .......................................................................... 8-56 Brake fluid, changing .................................................... 8-49 Brake fluid level, checking ............................................ 8-48 Brake hose protectors, checking the rear .................... 8-47 Brake lever, front .......................................................... 4-14 Brake levers, checking and lubricating ......................... 8-53 Brake pads, checking the front and rear ...................... 8-46 Brake pedal and rear brake lever ................................. 4-14 Brake pedal, checking and lubricating ......................... 8-54 Brake pedal free play, adjusting ................................... 8-50 Brakes .......................................................................... 8-46 Brakes, front and rear .................................................... 5-3 F Final gear oil .......................................................... 5-3, 8-27 Four-wheel-drive/differential gear lock indicator ............ 4-4 Front and rear brake lever free play, checking ............. 8-50 Fuel ....................................................................... 4-16, 5-3 Fuel tank cap ................................................................ 4-15 Fuses, replacing ........................................................... 8-59 H C Cables, checking and lubricating ................................. 8-53 Carrier, front ................................................................. 4-22 Carrier, rear .................................................................. 4-22 Chassis fasteners ........................................................... 5-6 Cleaning ......................................................................... 9-1 Coolant ..................................................................5-3, 8-32 Coolant temperature warning light ................................. 4-3 D Differential gear oil ................................................5-3, 8-29 Handlebar switches ........................................................ 4-7 Headlight beam, adjusting ............................................ 8-63 Headlight bulb, replacing .............................................. 8-61 High-range indicator light ............................................... 4-2 I Identification numbers .................................................. 11-1 Indicator lights and warning lights .................................. 4-2 Instruments, lights and switches .................................... 5-7 K Key identification number ............................................. 11-1 U1HS10E0.book Page 2 Wednesday, April 13, 2011 10:29 AM L Seat ............................................................................. 4-18 Shock absorber assemblies, adjusting the front and rear ............................................................................ 4-22 Spark arrester, cleaning ............................................... 8-42 Spark plug, checking ................................................... 8-20 Specifications ............................................................... 10-1 Speed limiter ................................................................ 4-13 Stabilizer bushes, checking ......................................... 8-55 Starting the engine ......................................................... 6-1 Start switch .................................................................... 4-8 Steering shaft, lubricating ............................................ 8-56 Storage .......................................................................... 9-2 Storage compartments ................................................ 4-19 Label locations ............................................................... 1-1 Light switch .................................................................... 4-8 Low-range indicator light ................................................ 4-2 M 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 Multi-function display ..................................................... 4-5 N Neutral indicator light ..................................................... 4-2 Noise regulation ........................................................... 11-4 O On-Command differential gear lock switch .................. 4-10 On-Command four-wheel-drive switch ........................... 4-9 Override switch .............................................................. 4-8 Owner’s manual and tool kit ........................................... 8-2 P Panels, removing and installing ................................... 8-10 Park indicator light ......................................................... 4-2 Parking ........................................................................... 6-5 Parking on a slope ......................................................... 6-5 Part locations ................................................................. 3-1 R Radiator grills, removing .............................................. 8-20 Rear knuckle pivots, lubricating ................................... 8-55 Reverse indicator light ................................................... 4-2 Riding your ATV ............................................................. 7-1 S Safety information .......................................................... 2-1 T Tail/brake light bulb, replacing ..................................... 8-63 Throttle lever ......................................................... 4-13, 5-4 Throttle lever free play, adjusting ................................. 8-45 Tires ............................................................................... 5-4 Troubleshooting ........................................................... 8-66 Troubleshooting charts ................................................ 8-67 V Valve clearance ........................................................... 8-46 V-belt case drain plug .................................................. 8-44 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 ..................................... 8-55 Wheel, installing ........................................................... 8-65 Wheel, removing .......................................................... 8-64 U1HS10E0.book Page 3 Wednesday, April 13, 2011 10:29 AM U1HS10E0.book Page 1 Wednesday, April 13, 2011 10:29 AM EBU30390 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect. Why settle for aftermarket parts that may not provide full confidence and satisfaction? Genuine Yamaha Accessories – Yamaha only offers accessories that meet our high standards for quality and performance. Buy with confidence, knowing your Genuine Yamaha Accessories will fit right and perform right – right out of the box. Yamalube – Take care of your Yamaha with legendary Yamalube oils, lubricants, and care products. They’re formulated and approved by the toughest judges we know: the Yamaha engineering teams that know your Yamaha from the inside out. Genuine Yamaha Service Manuals – Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use. Service manuals are available through your Yamaha dealer or you can order them directly through yamahapubs.com. Genuine Yamaha products are available only from your Yamaha dealer. Find out more at yamaha-motor.com EBU26151 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) PRINTED IN USA 2011.05-1.7×1 CR (E) DIC2342