Yamaha yfz 450r manual

This A OWNER’S MANUAL LIT -1 1626-22-75 18P-28199-10 This ATV should not be ridden by anyone under 16 years of age. YFZ450RY WARNING READ THIS MANUAL CAREFULLY! It contains important safety information.[...]

EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.[...]

EBU17170 INTRODUCTION EBU17301 Congratulations on your purchase of the Yamaha YFZ450RY. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have ma[...]

EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: * Product and specifications are subject to change without notice. This is the safety alert symbol. It is used [...]

EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of m[...]

W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU17420 TABLE OF CONTENTS SAFETY INFORMATION .............................. 1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 2-1 DESCRIPTION .............................................. 3-1 Left view .....................[...]

OPERATION .................................................. 6-1 Starting the engine .................................... 6-1 Shifting ...................................................... 6-2 Engine break-in ......................................... 6-4 Parking ...................................................... 6-5 Parking on a slope ........[...]

Lubricating the swingarm pivots .............. 8-43 Lubricating the upper and lower arm pivots ..................................................... 8-44 Battery ..................................................... 8-45 Replacing the fuse .................................. 8-47 Replacing a headlight bulb ...................... 8-48 Adjusting a hea[...]

1-1 1 2 3 4 5 6 7 8 9 10 11 EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU29350 AN ATV IS NOT A TOY AND CAN BE HAZARD- OUS TO OPERATE. An ATV handles differently from other vehicles, in- cluding motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles,[...]

1-2 1 2 3 4 5 6 7 8 9 10 11 that is proper for the terrain, visibility, operating conditions, and your experience. ● Never attempt wheelies, jumps, or other stunts. ● Always inspect your ATV each time you use it to make sure it is in safe operating condition. Al- ways follow the inspection and maintenance procedures and schedules described in t[...]

1-3 1 2 3 4 5 6 7 8 9 10 11 ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill. Turn the ATV around and remount, following the procedure described in this ma[...]

1-4 1 2 3 4 5 6 7 8 9 10 11 EWB02320 EWB00030 W ARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or[...]

2-1 1 2 3 4 5 6 7 8 9 10 11 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 5 6 3 2 1 6 4[...]

2-2 1 2 3 4 5 6 7 8 9 10 11 EBU17670 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.[...]

2-3 1 2 3 4 5 6 7 8 9 10 11 W ARNING UNDER 16 NEVER operate this A TV if y ou are under age 16 . 1 W ARNING Improper A TV use can result in SEVERE INJUR Y or DEA TH. AL WA YS USE NEVER USE NEVER CARR Y NEVER USE AN APPRO VED ON PUBLIC P ASSENGERS WITH DR UGS HELMET AND RO ADS OR ALCOHOL PRO TECTIVE GEAR NEVER operate : without proper training or in[...]

2-4 1 2 3 4 5 6 7 8 9 10 11 WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. Do not incinerate, puncture or open. 4AA-22259-80 W ARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 5FE-2151H-01 4 5 6 WA R N IN[...]

3-1 1 2 3 4 5 6 7 8 9 10 11 EBU17680 DESCRIPTION EBU17690 Left view EBU17700 Right view 1. F ront shock absorber assemb ly compression damping force adjusting bolt (f or f ast compression damping) 2. F ront shock absorber assemb ly compression damping force adjusting scre w (f or slow compression damping) 3. Headlights 4. Front shoc k absorber asse[...]

3-2 1 2 3 4 5 6 7 8 9 10 11 EBU17712 Controls and instruments TIP The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Clutch le v er 2. P arking brake le ver 3. Left handlebar s witches 4. Fuel tank cap 5. Main s witch 6. Throttle le v er 7. Brak e le v er 2 1 3 6 5 7 4[...]

4-1 1 2 3 4 5 6 7 8 9 10 11 EBU17724 INSTRUMENT AND CONTROL FUNCTIONS W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU17760 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, [...]

4-2 1 2 3 4 5 6 7 8 9 10 11 EBU29380 Indicator light and warning lights EBU17860 Neutral indicator light “” This indicator light comes on when the transmis- sion is in the neutral position. EBU26700 Coolant temperature warning light “” This warning light comes on when the engine over- heats. When this occurs during operation, stop the engin[...]

4-3 1 2 3 4 5 6 7 8 9 10 11 EBU26720 Engine trouble warning light “” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warni[...]

4-4 1 2 3 4 5 6 7 8 9 10 11 turned off for an extended period of time, oth- erwise 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. EBU18270 Throttle lever Once the engine is running, movement of the throt- tle lever will increase the engine speed. Re[...]

4-5 1 2 3 4 5 6 7 8 9 10 11 EBU18311 Speed limiter Your ATV was delivered 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 avail- able and the maximum speed of the ATV, turn the adjusting sc[...]

4-6 1 2 3 4 5 6 7 8 9 10 11 EWB00190 EBU18382 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporat- ed in the clutch lever holder. To disengage the clutch, pull the clutch lever toward the handlebar grip. To engage the clutch, release the clutch lever. The clutch lever should be pulled[...]

4-7 1 2 3 4 5 6 7 8 9 10 11 EBU18432 Brake pedal The brake pedal is located on the right side of the ATV. To apply the rear brake, push down on the brake pedal. EBU18510 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in directio[...]

4-8 1 2 3 4 5 6 7 8 9 10 11 EWB00170 EBU18530 Shift pedal This ATV is equipped with a constant-mesh 5- speed transmission. The shift pedal is located on the left side of the engine and is used in combina- tion with the clutch when shifting. 1. P arking brake le ver (loc ked position) 1. P arking brake le ver (unloc ked position) W ARNING POTENTIAL [...]

4-9 1 2 3 4 5 6 7 8 9 10 11 EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. EBU18800 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 1. Shift pedal 1 1. Fuel tank cap 1[...]

4-10 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00070 Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number [(R+M)/2] of 91 or higher, or a [...]

4-11 1 2 3 4 5 6 7 8 9 10 11 EBU18890 Seat To remove the seat Insert your hand between the rear of the seat and the rear fender, pull the seat lock lever upward and pull up the seat at the rear. 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. TIP Make sure that the sea[...]

4-12 1 2 3 4 5 6 7 8 9 10 11 EBU29291 Adjusting the front shock absorber assemblies These shock absorber assemblies are equipped with a spring preload adjusting nut, a rebound damping force adjusting screw, with a compres- sion damping force adjusting bolt (for fast com- pression damping), and a compression damping force adjusting screw (for slow c[...]

4-13 1 2 3 4 5 6 7 8 9 10 11 the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension. TIP ● A special wrench can be obtained at a Yamaha dealer to make this adjustment. ● The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the hig[...]

4-14 1 2 3 4 5 6 7 8 9 10 11 3. Tighten the locknut to the specified torque. NOTICE ECB00080 Always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque. Rebound damping force Turn the adjusting screw in direction (a) to increase the rebound damping force and thereby harden the damping, and in direction (b) t[...]

4-15 1 2 3 4 5 6 7 8 9 10 11 Compression damping force Compression damping force (for fast compression damping) To increase the compression damping force and thereby harden the compression damping, turn the adjusting bolt in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting bolt [...]

4-16 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00090 Never turn an adjusting mechanism beyond the minimum and maximum settings. TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always rep- resents the entire adjus[...]

4-17 1 2 3 4 5 6 7 8 9 10 11 EWB00350 EBU29512 Adjusting the rear shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting nut, a rebound damping force adjusting screw, with a compression damp- ing force adjusting bolt (for fast compression damping), and a compression damping force ad- justing screw (for slow[...]

4-18 1 2 3 4 5 6 7 8 9 10 11 Spring preload 1. Remove panel C. (See page 8-8.) 2. Loosen the clamp screw at the throttle body side, and then disconnect the air intake duct from the throttle body. 3. Disconnect the coupler. 4. Loosen the clamp screw at the air filter case side, and then disconnect the air intake duct from the air filter case. 1. Cla[...]

4-19 1 2 3 4 5 6 7 8 9 10 11 5. Remove the air filter case holding plate by re- moving the bolts and collars. 6. Remove the blow-by gas chamber by remov- ing the bolt. 1. Clamp scre w 1 1. Bolt 2. Collar 3. Air filter case holding plate 1 1 2 3[...]

4-20 1 2 3 4 5 6 7 8 9 10 11 7. Remove the air filter case by removing the bolts. 8. Loosen the locknut. 9. Turn the adjusting nut in direction (a) to in- crease the spring preload and thereby harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension. 1. Blow-b y gas chamber 2. Bolt 1 2 1. Air ?[...]

4-21 1 2 3 4 5 6 7 8 9 10 11 TIP ● A special wrench can be obtained at a Yamaha dealer to make this adjustment. ● The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the higher the spring preload; the longer distance A is, the lower the spring preload. With each complete turn o[...]

4-22 1 2 3 4 5 6 7 8 9 10 11 10. Tighten the locknut to the specified torque. NOTICE ECB00080 Always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque. 11. Place the air filter case in the original position, install the bolts, and then tighten them to the specified torque. 12. Connect the air intake duct t[...]

4-23 1 2 3 4 5 6 7 8 9 10 11 rebound damping force and thereby soften the damping. TIP Make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting. Compression damping force Panels A and D need to be removed to make this adjustment. (See page 8-8.) Compression damping force (for fast compr[...]

4-24 1 2 3 4 5 6 7 8 9 10 11 Compression damping force (for slow compres- sion damping) To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b). 1. C[...]

4-25 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00090 Never turn an adjusting mechanism beyond the minimum and maximum settings. TIP ● Make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting(s). ● Although the total number of clicks of a damping force adjusting mechanism may not exactly mat[...]

4-26 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. 1. Handlebar 1[...]

5-1 1 2 3 4 5 6 7 8 9 10 11 EBU19200 PRE-OPERATION CHECKS EBU19213 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. EWB00470 TIP The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which servi[...]

5-2 1 2 3 4 5 6 7 8 9 10 11 ITEM ROUTINE P A GE Fuel ● Check fuel le v el in fuel tank, and add recommended fuel if neces- sary . ● Check fuel line f or leakage. Correct if necessar y . 4-9, 5-4 Engine oil ● Check oil le v el in engine, and add recommended oil to specified lev el if necessary . ● Check A TV f or oil leakage. Correct if nec[...]

5-3 1 2 3 4 5 6 7 8 9 10 11 Wheels and tires ● Check wheel condition, and replace if damaged. ● Check tire condition and tread depth. Replace if necessar y . ● Check air pressure . Correct if necessary . 5-6, 5-7, 5-8 Shift pedal ● Make sure that operation is smooth. ● Correct if necessary . 8-43 Brake pedal ● Make sure that operation i[...]

5-4 1 2 3 4 5 6 7 8 9 10 11 EBU19530 Fuel Make sure that there is sufficient fuel in the tank. (See page 4-9.) EWB00500 EBU19560 Engine oil Make sure that the engine oil is at the specified lev- el. Add oil as necessary. (See page 8-14.) EBU19620 Coolant Make sure that the coolant is at the specified level. Add coolant as necessary. (See page 8-19.[...]

5-5 1 2 3 4 5 6 7 8 9 10 11 EBU19700 Front and rear brakes Brake lever and brake pedal ● Check that there is no free play in the brake le- ver. If there is free play, have a Yamaha dealer check the brake system. ● Check for correct brake pedal height. (See page 8-34.) If the pedal height is incorrect, have a Yamaha dealer adjust it. ● Check t[...]

5-6 1 2 3 4 5 6 7 8 9 10 11 necessary. EBU19770 Drive chain Check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the drive chain as necessary. (See page 8-38.) EBU19782 Tires EWB00562 W ARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Us[...]

5-7 1 2 3 4 5 6 7 8 9 10 11 EBU19821 Measuring the tire pressure Use the low-pressure tire gauge. TIP The low-pressure tire gauge is included as stan- dard 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. ● The tires should be set to the reco[...]

5-8 1 2 3 4 5 6 7 8 9 10 11 Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and[...]

6-1 1 2 3 4 5 6 7 8 9 10 11 EBU19871 OPERATION W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU19890 EWB00610 EBU29472 Starting the engine EWB00620 NOTICE ECB00150 See the “ Engine break-in ” section on page 6-4 prior to operating the engine for the first time. 1. Set the parking brake. 2. Turn th[...]

6-2 1 2 3 4 5 6 7 8 9 10 11 level warning light and engine trouble warning light should come on, then go off. If a warning light does not go off, see page 4-2 for the corresponding warning light circuit check. 3. Shift the transmission into neutral. The neutral indicator light should come on, if it does not come on, have a Yamaha dealer check the e[...]

6-3 1 2 3 4 5 6 7 8 9 10 11 EBU20580 To start out and accelerate 1. Release the throttle lever, and then release the parking brake. NOTICE ECB00200 Always close the throttle before shifting gears, otherwise damage to the engine and drive train may result. 2. Pull the clutch lever to disengage the clutch. 3. Shift into first gear. 4. Open the thrott[...]

6-4 1 2 3 4 5 6 7 8 9 10 11 tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an accident. EWB00650 NOTIC[...]

6-5 1 2 3 4 5 6 7 8 9 10 11 operation or any condition that might result in en- gine overheating must be avoided. 0 – 160 km (0 – 100 mi) or 0 – 10 hours Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position. 160 – 320 km (100 – 200 mi) or 10 – 20 hours Avoid pr[...]

6-6 1 2 3 4 5 6 7 8 9 10 11 EBU20850 Parking on a slope EWB00790 1. Bring the ATV to a stop by applying the brakes in first gear. 2. Stop the engine and release the clutch lever. 3. With the rear brake applied, apply the parking brake and slowly release the brake pedal. EBU20910 Accessories and loading EBU20920 Accessories Accessories can affect th[...]

6-7 1 2 3 4 5 6 7 8 9 10 11 ity or suitability. Choose a genuine Yamaha ac- cessory, or one that is equivalent in design and quality. ● 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 coul[...]

6-8 1 2 3 4 5 6 7 8 9 10 11 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. EWB00750 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. W ARNING POTENTIAL H[...]

7-1 1 2 3 4 5 6 7 8 9 10 11 EBU21131 RIDING YOUR ATV[...]

7-2 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU21593 GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by expe- rienced operators only. Even if you are an experi- enced operator of all other all terrain ATVs or motorcycles, riding the ATV requires special [...]

7-3 1 2 3 4 5 6 7 8 9 10 11 Riding your ATV requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Not recommended for children under 16 years of age. EWB00901 HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certi[...]

7-4 1 2 3 4 5 6 7 8 9 10 11 This ATV is designed to carry operator only – passengers prohibited. EWB00910 Apparel EWB00920 W ARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger. HOW TO AVOID[...]

7-5 1 2 3 4 5 6 7 8 9 10 11 Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci- dent. Operating without eye protection [...]

7-6 1 2 3 4 5 6 7 8 9 10 11 EWB00930 Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety. EWB00940 EWB00950 W ARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to [...]

7-7 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. EWB00960 Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a speed lim- iter. The speed limiter keeps the t[...]

7-8 1 2 3 4 5 6 7 8 9 10 11 Loading and accessories As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add ac- cessories so that you can carry cargo or tow a trail- er, you must use common sense and good judgment. Use extra caution when riding the ATV with addi- tional loads, such as accessories or ca[...]

7-9 1 2 3 4 5 6 7 8 9 10 11 During operation Always keep your feet on the footboards during op- eration, otherwise they may contact the rear wheels. EWB00980 Avoid wheelies and jumping. You may lose control of the ATV or overturn. EWB00990 W ARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HA[...]

7-10 1 2 3 4 5 6 7 8 9 10 11 Modifications EWB01000 Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. EWB01010 W ARNING POTENTIAL HAZARD Operating this ATV with improper modifi[...]

7-11 1 2 3 4 5 6 7 8 9 10 11 BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. EWB01020 HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material. Do not tou[...]

7-12 1 2 3 4 5 6 7 8 9 10 11 Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. EWB01030 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. W ARNING[...]

7-13 1 2 3 4 5 6 7 8 9 10 11 EWB01040 W ARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful wh[...]

7-14 1 2 3 4 5 6 7 8 9 10 11 EWB01050 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. W ARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause[...]

7-15 1 2 3 4 5 6 7 8 9 10 11 EWB01060 Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. 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 proce[...]

7-16 1 2 3 4 5 6 7 8 9 10 11 the shift pedal. Remember that the engine and ex- haust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then release the parking brake. Open the thrott[...]

7-17 1 2 3 4 5 6 7 8 9 10 11 EWB01070 TURNING YOUR ATV To achieve maximum traction while riding off-road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. There- fore, unless the wheel on the inside of the turn is al- lowed to slip or lose some traction, the ATV will resist turning. A special turning techniqu[...]

7-18 1 2 3 4 5 6 7 8 9 10 11 This procedure should be practiced at slow speed many times in a large off-road area with no obsta- cles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesn’t turn, come to a stop and then practice the proce- dure again. If the riding surface is slippery or loose, it may help to [...]

7-19 1 2 3 4 5 6 7 8 9 10 11 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. EWB01100 WHAT CAN HAPPEN The ATV can overturn more easily on ex- tremely steep hi[...]

7-20 1 2 3 4 5 6 7 8 9 10 11 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. EWB01190 W ARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WH[...]

7-21 1 2 3 4 5 6 7 8 9 10 11 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 up- hill side. Physically turn the ATV around and then descend the hil[...]

7-22 1 2 3 4 5 6 7 8 9 10 11 RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- sible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the en- gine compression to do most of the braking for you. Improper braking may cause a loss of trac- ti[...]

7-23 1 2 3 4 5 6 7 8 9 10 11 CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slip- pery surfaces or rough terrain that may upset your[...]

7-24 1 2 3 4 5 6 7 8 9 10 11 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[...]

7-25 1 2 3 4 5 6 7 8 9 10 11 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 care- fully. EWB01150 Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you hav[...]

7-26 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00240 After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Loo[...]

7-27 1 2 3 4 5 6 7 8 9 10 11 SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will someti[...]

7-28 1 2 3 4 5 6 7 8 9 10 11 With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are re- duced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all[...]

7-29 1 2 3 4 5 6 7 8 9 10 11 Lean more into the turn to regain balance. If nec- essary, gradually let off the throttle and/or steer to the outside of the turn. (See page 7-17.) ● 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 cor[...]

8-1 1 2 3 4 5 6 7 8 9 10 11 EBU21648 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21660 Safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your ATV in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages.[...]

8-2 1 2 3 4 5 6 7 8 9 10 11 The service information included in this manual and the tools provided in the owner’s tool kit are in- tended to assist you in the performance of preven- tive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. TIP If you do no[...]

8-3 1 2 3 4 5 6 7 8 9 10 11 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 inter- vals. However, keep in mind that if the ATV i[...]

8-4 1 2 3 4 5 6 7 8 9 10 11 EBU21864 General maintenance and lubrication chart NO . ITEM CHECK OR MAINTENANCE JOB INITIAL EVER Y Whiche v- er comes fi rst month 1366 1 2 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 Air fi lter element ● Clean and replace if necessary . Every 20–40 hours (more ofte[...]

8-5 1 2 3 4 5 6 7 8 9 10 11 10 * Swingarm pivots ● Check operation and f or e xcessive pla y , and replace bearings if necessar y . ● Lubricate with lithium-soap-based grease. √√√ 11 * Upper and lower arm pivots ● Lubricate with lithium-soap-based grease. √√√ 12 Drive chain ● Check chain slac k and adjust if necessar y . ● Che[...]

8-6 1 2 3 4 5 6 7 8 9 10 11 20 Engine oil ● Change. ● Check A TV f or oil leakage, and correct if neces- sary . √ √√√ 21 Engine oil fi lter ele- ment ● Replace. √√√ 22 Cooling system ● Check coolant le v el and A TV for coolant leakage, and correct if necessary . √√√√√ ● Replace coolant. Every 2 years 23 * Moving [...]

8-7 1 2 3 4 5 6 7 8 9 10 11 EBU29430 TIP ● Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● Replace the fuel hose every five years and if cracked or damaged. ● Hydraulic brake service ● Regularly check and, if necessary, correct the brake fluid level. ?[...]

8-8 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. EBU29531 Pa[...]

8-9 1 2 3 4 5 6 7 8 9 10 11 4. Remove the quick fasteners, and then slide the panel backward and pull upward. To install the panel 1. Place the panel in the original position, and then install the quick fasteners. 1. Bolt 1 1 1. Quic k f astener 1[...]

8-10 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00380 When installing the panel, be sure not to pinch the cables or wires. 2. Install the bolts. 3. Install the fuel tank cap. Panels B and D To remove one of the panels 1. Remove panel A. 2. Pull the panel off. To install one of the panels 1. Place the panel in its original position. 1. Projection 2. Slot 1 1[...]

8-11 1 2 3 4 5 6 7 8 9 10 11 2. Install panel A. Panel C To remove the panel 1. Remove panels A, B and D. 2. Remove the bolts, and then take the panel off. To install the panel Place the panel in its original position, and then in- stall the bolts. Panel E To remove the panel 1. Remove panel A. 2. Remove the bolts, and then take the panel off. 1. B[...]

8-12 1 2 3 4 5 6 7 8 9 10 11 To install the panel 1. Place the panel in the original position and in- stall the bolts. 2. Install panel A. Panel F To remove the panel 1. Remove panel E. 2. Remove the bolts, and then take the panel off. To install the panel 1. Place the panel in the original position and in- stall the bolts. 1. Bolt 1. Bolt 1 1 1 1 [...]

8-13 1 2 3 4 5 6 7 8 9 10 11 2. Install panel E. EBU29440 Checking the spark plug The spark plug is an important engine component, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic main[...]

8-14 1 2 3 4 5 6 7 8 9 10 11 TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. EBU29492 Engine oil and oil filter element The engine oil level should be checked befor[...]

8-15 1 2 3 4 5 6 7 8 9 10 11 and maximum level marks. 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type through the engine oil tank filler hole to raise it to the correct level. TIP When adding oil, be careful not to overfill the en- gine oil tank; the oil level rises faster starting from the h[...]

8-16 1 2 3 4 5 6 7 8 9 10 11 6. Remove the engine oil tank filler cap and the engine oil tank drain bolt. 7. Check the washers for damage, and replace if necessary. TIP Skip steps 8–11 if the oil filter element is not being replaced. 8. Remove the oil filter element cover by remov- ing the bolts, and then remove the oil filter el- ement. 1. Crank[...]

8-17 1 2 3 4 5 6 7 8 9 10 11 9. Check the O-rings for damage, and replace them if necessary. 10. Install a new oil filter element and the O-rings. TIP Make sure that the O-rings are properly seated. 11. Install the oil filter element cover by installing the bolts, and then tighten them to the speci- fied torque. 1. Oil filter element cov er 2. Bol[...]

8-18 1 2 3 4 5 6 7 8 9 10 11 12. Install the crankcase engine oil drain bolt and the engine oil tank drain bolt, and then tighten them to their specified torques. 13. Pour the specified amount of the recommend- ed engine oil through the engine oil tank filler hole, and then install and tighten the engine oil tank filler cap. TIP Be sure to wipe off[...]

8-19 1 2 3 4 5 6 7 8 9 10 11 minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 15. Turn the engine off, and then check the oil lev- el and correct it if necessary. 16. Install the engine guard by installing the bolts, and then tighten them to the specified torque. NOTICE ECB00370 [...]

8-20 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00401 ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard wa- ter or salt water since it is harmful to the en- gine. ● If water has been used instead of coolant, re- place it with coolant as soon as possible, otherwise the cooling system will not be pro- tected aga[...]

8-21 1 2 3 4 5 6 7 8 9 10 11 EBU23551 To change the coolant EWB01880 1. Place the ATV on a level surface. 2. Remove panel F. (See page 8-8.) 3. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object as shown.) 4. Remove the radiator cap. W ARNING POTENTIAL HAZARD Removing the radiator cap when [...]

8-22 1 2 3 4 5 6 7 8 9 10 11 5. Remove the coolant reservoir by removing the bolts. 6. Remove the coolant reservoir cap, and then turn the coolant reservoir upside down to empty it. 7. After draining the coolant, thoroughly flush the cooling system with clean tap water. 8. Install the coolant reservoir by installing the bolts. 9. Replace the coolan[...]

8-23 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00401 ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard wa- ter or salt water since it is harmful to the en- gine. ● If water has been used instead of coolant, re- place it with coolant as soon as possible, otherwise the cooling system will not be pro- tected aga[...]

8-24 1 2 3 4 5 6 7 8 9 10 11 1. Place the ATV on a level surface. 2. Remove the seat. (See page 4-11.) 3. Remove the air filter case cover by unhooking the holders. 4. Loosen the wing bolt. 5. Remove the air filter element together with the wing bolt and washer. 1. Air filter case check hose 1 1. Air filter case cov er 2. Air filter case cov er [...]

8-25 1 2 3 4 5 6 7 8 9 10 11 6. Remove the wing bolt and washer from the air filter element. 7. Remove the sponge material from the air filter element frame. 8. Wash the sponge material gently but thor- oughly in solvent. EWB01900 1. Wing bolt 2. Air filter element 1 2 1. Sponge material 2. Air filter element frame W ARNING POTENTIAL HAZARD Using[...]

8-26 1 2 3 4 5 6 7 8 9 10 11 9. Squeeze the excess solvent out of the sponge material and let it dry. NOTICE ECB00440 Do not twist the sponge material when squeez- ing it. 10. Check the sponge material and replace it if damaged. 11. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. TIP The sponge materi[...]

8-27 1 2 3 4 5 6 7 8 9 10 11 14. Insert the air filter element into the air filter case, and then tighten the wing bolt. 15. Install the air filter case cover by hooking the holders onto the air filter case. 16. Install the seat. TIP The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the[...]

8-28 1 2 3 4 5 6 7 8 9 10 11 brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the bolt and tighten it to the specified torque. 6. Remove the purging bolt. 7. Start the engine and rev it up approximately[...]

8-29 1 2 3 4 5 6 7 8 9 10 11 EWB01930 EBU24045 Adjusting the throttle cable free play The throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in the periodic maintenance and lubrication chart. The throttle cable free play should measure 2.0– 4.0 mm (0.08–0.16 in) at the throttle lever. Period- ica[...]

8-30 1 2 3 4 5 6 7 8 9 10 11 4. Tighten the locknut. 5. Slide the rubber cover to its original position. EBU24060 Valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in th[...]

8-31 1 2 3 4 5 6 7 8 9 10 11 TIP The wheels need to be removed to check the brake pads. (See page 8-50.) EBU26460 Rear brake pads Each rear brake pad is provided with wear indica- tor grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indi- cator grooves. If a br[...]

8-32 1 2 3 4 5 6 7 8 9 10 11 brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Front brake Rear brake TIP To check the rear brake fluid level, remove the seat. (See page 4-11.) Observe these precautions: ● When checking the fluid level, make sure tha[...]

8-33 1 2 3 4 5 6 7 8 9 10 11 ● Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. ● Be careful that water does not enter the brake fluid reservoir when refilling. Water will signifi- cantly lower the boiling point of the fluid and may result in vapor lock. ● [...]

8-34 1 2 3 4 5 6 7 8 9 10 11 EBU24601 Checking the brake pedal position The brake pedal position must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The top of the brake pedal should be positioned 11.7 mm (0.46 in) below the top of the footrest as shown. If the brake pedal is not[...]

8-35 1 2 3 4 5 6 7 8 9 10 11 EWB02060 EBU24700 Adjusting the parking brake free play The parking brake free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Cable length “A” should measure 47–51 mm (1.9– 2.0 in). Adjust the parking brake free play as fol- lows. 1.[...]

8-36 1 2 3 4 5 6 7 8 9 10 11 TIP If the cable length cannot be adjusted to specifica- tion, consult a Yamaha dealer. 5. Tighten the locknut on the brake cable. 6. Turn in the adjusting bolt at the rear brake cal- iper until it feels tight, then turn it out 1/8 turn and tighten its locknut to the specified torque. NOTICE ECB00520 When tightening the[...]

8-37 1 2 3 4 5 6 7 8 9 10 11 vals specified in the periodic maintenance and lu- brication chart. The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. TIP The brake light switch is properly adjusted when the brake light comes on just before braking takes effe[...]

8-38 1 2 3 4 5 6 7 8 9 10 11 1. To increase the clutch lever free play, turn the adjusting nut at the clutch lever in direction (a), and to decrease it, turn the nut in direction (b). If the specified free play cannot be obtained, proceed with the following steps. 2. Fully turn the adjusting nut at the clutch lever in direction (a) to loosen the cl[...]

8-39 1 2 3 4 5 6 7 8 9 10 11 To check the drive chain slack 1. Place the ATV on a level surface. TIP When checking and adjusting the drive chain slack, there should be no weight on the ATV and all tires must be touching the ground. 2. Move the ATV back and forth to locate the tightest portion of the drive chain, and then measure the drive chain sla[...]

8-40 1 2 3 4 5 6 7 8 9 10 11 TIP A rod can be obtained at a Yamaha dealer to make this adjustment. 4. Shift the transmission into neutral. 5. To tighten the drive chain, push the ATV back- ward. To loosen the drive chain, push the ATV forward. NOTICE ECB00541 Improper drive chain slack will overload the en- gine as well as other vital parts of the [...]

8-41 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00560 The drive chain must be lubricated after wash- ing the ATV or riding in the rain. 1. Clean the drive chain with kerosene and a small soft brush. NOTICE ECB00570 To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pres- sure washers or inappropriate solvents. 2. Wipe th[...]

8-42 1 2 3 4 5 6 7 8 9 10 11 EWB02120 EBU24922 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Brake lever Clutch lever W ARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result w[...]

8-43 1 2 3 4 5 6 7 8 9 10 11 EBUM0170 Checking the shift pedal The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle. EBU28871 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be l[...]

8-44 1 2 3 4 5 6 7 8 9 10 11 EBU25032 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun. Left side Recommended lubricant: Lithium-soap-based grease 1. Upper grease nipple 2. Lowe[...]

8-45 1 2 3 4 5 6 7 8 9 10 11 Right side EBU29172 Battery This model is equipped with a VRLA (Valve Regu- lated 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. NOTICE ECB00620 Never attempt to remove the battery cell seals,[...]

8-46 1 2 3 4 5 6 7 8 9 10 11 To remove the battery 1. Remove the seat. (See page 4-11.) 2. Remove the battery holding plate by removing the bolts. 3. Disconnect the negative battery lead first, then the positive battery lead by removing their bolt. 4. Pull the battery out of its compartment. To charge the battery Have a Yamaha dealer charge the bat[...]

8-47 1 2 3 4 5 6 7 8 9 10 11 charged battery can cause permanent battery damage. To install the battery TIP Be sure the battery is fully charged. 1. Place the battery in its compartment. 2. Connect the positive battery lead first, then the negative battery lead by installing their bolt. 3. Install the battery holding plate by installing the bolts. [...]

8-48 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00640 To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. EWB02151 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse imm[...]

8-49 1 2 3 4 5 6 7 8 9 10 11 EWB02180 4. Place a new headlight bulb into position. NOTICE ECB00650 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 affect- ed. Thoroughly clean off any dirt and finger- prints on the he[...]

8-50 1 2 3 4 5 6 7 8 9 10 11 7. Install the panel. 8. Adjust the headlight beam if necessary. EBU25551 Adjusting a headlight beam NOTICE ECB00690 It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in di[...]

8-51 1 2 3 4 5 6 7 8 9 10 11 Rear 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. EBU25681 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts. TIP ● When installing a front wheel, make sure its ar- row mark points toward the rotating dire[...]

8-52 1 2 3 4 5 6 7 8 9 10 11 EBU25730 Troubleshooting Although Yamaha ATVs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and[...]

8-53 1 2 3 4 5 6 7 8 9 10 11 EBU27681 Troubleshooting charts Starting problems or poor engine performance 1. Fuel 2. Compression 3. Ignition 4. Battery[...]

8-54 1 2 3 4 5 6 7 8 9 10 11 Engine overheating EWB02270 TIP If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible. W ARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot [...]

9-1 1 2 3 4 5 6 7 8 9 10 11 EBU25860 CLEANING AND STORAGE EBU25890 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 an[...]

9-2 1 2 3 4 5 6 7 8 9 10 11 EWB02300 EBU27260 Storage Short-term Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover. NOTICE ECB00720 ● 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 [...]

9-3 1 2 3 4 5 6 7 8 9 10 11 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[...]

10-1 1 2 3 4 5 6 7 8 9 10 11 EBU25960 SPECIFICATIONS EBU2597D Dimensions: Overall length: 1795 mm (70.7 in) Overall width: 1240 mm (48.8 in) Overall height: 1065 mm (41.9 in) Seat height: 810 mm (31.9 in) Wheelbase: 1270 mm (50.0 in) Ground clearance: 235 mm (9.3 in) Minimum turning radius: 3600 mm (142 in) Weight: With oil and fuel: 184.0 kg (406 [...]

10-2 1 2 3 4 5 6 7 8 9 10 11 Engine oil quantity: Without oil filter element replacement: 1.40 L (1.48 US qt, 1.23 Imp.qt) With oil filter element replacement: 1.45 L (1.53 US qt, 1.28 Imp.qt) Cooling system: Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt, 0.22 Imp.qt) Radiator capacity (including all routes): 1.25 L [...]

10-3 1 2 3 4 5 6 7 8 9 10 11 Trail: 21.0 mm (0.83 in) Front tire: Type: Tubeless Size: AT21 x 7R-10 Manufacturer/model: DUNLOP/KT351 Radial Rear tire: Type: Tubeless Size: AT20 x 10R-9 Manufacturer/model: DUNLOP/KT356 Radial Loading: Maximum loading limit: 100.0 kg (220 lb) (Total weight of rider, cargo, accessories, and tongue) Tire air pressure ([...]

10-4 1 2 3 4 5 6 7 8 9 10 11 Rear suspension: Type: Swingarm (link suspension) Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 280 mm (11.0 in) Electrical system: Ignition system: TCI (digital) Charging system: AC magneto Battery: Model: YTZ-7S Voltage, capacity: 12 V, 6.0 Ah Headlight: Bulb type: Krypton bulb Bulb voltage, wat[...]

11-1 1 2 3 4 5 6 7 8 9 10 11 EBU25981 CONSUMER INFORMATION EBU26011 Identification numbers Record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a Yamaha dealer or for ref- erence in case the ATV is stolen. ● KEY IDENTIFICATION[...]

11-2 1 2 3 4 5 6 7 8 9 10 11 TIP The vehicle identification number is used to identi- fy your ATV. EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- er. 1. V ehicle identi?[...]

11-3 1 2 3 4 5 6 7 8 9 10 11 EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new v[...]

11-4 1 2 3 4 5 6 7 8 9 10 11 EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.[...]

11-5 1 2 3 4 5 6 7 8 9 10 11 EBU26501 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY Y amaha Motor Corporation, U.S .A. hereby warr ants that new Y amaha A TVs purchased from an authorized Y amaha A TV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, sub- ject[...]

11-6 1 2 3 4 5 6 7 8 9 10 11 W ARRANTY QUESTIONS AND ANSWERS 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 . Q. What are some[...]

11-7 1 2 3 4 5 6 7 8 9 10 11 EBU26122 YAMAHA EXTENDED SERVICE (Y.E.S.) K eep your Y amaha protected even after y our warranty expires with gen uine Y amaha Extended Service (Y .E.S.). Y .E.S. is designed and administered by Y amaha Motor Corporation to provide maximum owner satisf action. Y ou get uninterrupted factory-backed co verage f or e xtra [...]

11-8 1 2 3 4 5 6 7 8 9 10 11 We urge y ou to act now . Y ou ’ ll get the excellent benefits of TRIP cov erage right awa y , and you ’ ll rest easy knowing you ’ ll ha ve strong f actory-backed protection e ven after y our Y amaha Limited W arranty e xpires. Y ou can also sav e money: Y .E.S. costs less within the first 90 da ys after you buy [...]

11-9 1 2 3 4 5 6 7 8 9 10 11 EBU26132[...]

INDEX A Accessories and loading ................................................ 6-6 Air filter element, cleaning ............................................ 8-23 B Battery .......................................................................... 8-45 Brake and clutch levers, checking and lubricating ....... 8-42 Brake fluid, changing............[...]

L Label locations ................................................................2-1 Light switch .....................................................................4-3 M Main switch .....................................................................4-1 Maintenance and lubrication chart ..................................8-4 Maintenance chart, [...]

PRINTED IN JAP AN 2008.09-4.4x2 ! (E) Y AMAHA MOT OR CO. , L TD. PRINTED ON RECYCLED PAPER LOCATE AND READ OWNER ’ S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) WARNING ALWAYS : use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. avoid paved surfaces-pave[...]

Dear New Y amaha A TV Owner: CONGRA TULA TIONS ON THE PURCHASE OF YOUR NEW Y AMAHA A TV . Y ou have purchased a quality Y amaha pr oduct that , with proper use and care , will pro vide hours of riding pleasure. BEFORE YOU OPERATE YOUR NEW ATV , Y amaha recommends these important points: 8 READ YOUR OWNER ’ S MANU AL 8 A CHILD UNDER 6 YEARS OLD S [...]

NO POST AGE NECESSARY IF MAILED IN THE UNITED ST A TES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POST AGE WILL BE P AID BY ADDRESSEE Y AMAHA MOTOR CORPORA TION U.S.A. P .O. BOX 6555 CYPRESS, CALIFORNIA 90630-9989 A TTN: SALES ADMINISTRA TION ATV card for US 4/2/03 9:06 AM Page 2[...]