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Yamaha GRIZZLY 450 YFM45FGY Owner's Manual
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Yamaha GRIZZLY 450 YFM45FGY Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
OWNER'S MANUAL
YFM45FGY
37S-F8199-60

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Summary of Contents for Yamaha GRIZZLY 450 YFM45FGY

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM45FGY 37S-F8199-60...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2008.06-0.9×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45FGY 37S-F8199-60-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 98 / 37 /EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM450FWAN (5Y4AJ14W080513201~)
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 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: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Fuel ............4-15 Fuel cock ..........4-16 LOCATION OF THE WARNING AND Starter (choke) ..........4-17 SPECIFICATION LABELS ......2-1 Seat ............4-18 Storage compartments ......4-19 DESCRIPTION ..........3-1 Front carrier ..........4-21 Left view ............3-1 Rear carrier ..........4-21 Right view............
  • Page 9 Instruments, lights and switches ....5-7 PERIODIC MAINTENANCE AND MINOR REPAIR ............8-1 OPERATION ..........6-1 Owner’s manual and tool kit .......8-1 Starting a cold engine ........ 6-1 Periodic maintenance chart for the Starting a warm engine ......6-3 emission control system ......8-3 Operating the drive select lever and General maintenance and lubrication driving in reverse ........
  • Page 10 Checking the front brake lever free CLEANING AND STORAGE ......9-1 play ............8-41 Cleaning ............9-1 Adjusting the brake pedal and rear brake Storage ............9-2 lever free play and checking the brake pedal position ......... 8-42 SPECIFICATIONS ........10-1 Axle boots ..........8-46 Brake light switches .........

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION EBU17502 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 12 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 13 steady speed when climbing a hill. If you stall or Always be sure there are no obstacles or people roll backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 14 nition such as the pilot lights of water heat- EWB00070 WARNING ers and clothes dryers. Gasoline can catch fire and you could be burned. Always operate your ATV in an area with ade- When transporting the ATV in another vehi- quate ventilation.

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 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. For Europe and Oceania ( 6 0 0 k g f )
  • Page 17 For Europe...
  • Page 18 For Europe MODEL: YFM450FWAN MAX. POWER: 19.4 kW MASS IN RUNNING ORDER: 285 kg 37S-F155A-00...
  • Page 19 For Oceania 25 kPa, (3.6 psi) 25 kPa, (3.6 psi) 22 kPa, (3.2 psi) 22 kPa, (3.2 psi) 5FU-F816M-20...
  • Page 20 For Oceania UNDER 1P0-F816L-00...
  • Page 21 For Oceania WARNING Fuel vapors can be a fire or explosion hazard. To avoid injury or death, never store fuel or flammable liquids in this storage compartment. Storage should not exceed 0.5 kg (1 lb) 37S-F151F-00...

  • Page 22: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 1. Rear shock absorber assembly spring preload adjusting ring 2. Fuel cock 2. Spark arrester 3. Recoil starter 3. Rear storage compartment and tool kit 4. Throttle stop screw 4.

  • Page 23: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly 6 7 8 from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Horn switch 5. Drive select lever 6. Multifunction display 7.

  • Page 24: Instrument And Control Functions

    EBU17732 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

  • Page 25: Indicator Lights And Warning Light

    10 seconds or more. If the indicator light flashes under any other circum- stances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. EBU17860 Neutral indicator light “...
  • Page 26 Start the engine after making sure that the EBU17970 Park indicator light “ ” warning light is out. Continuous use while This indicator light comes on when the transmis- the warning light is on may cause damage to sion is in the park position. the engine.

  • Page 27: Multifunction Display

    EBU18034 a clock Multifunction display an hour meter (which shows the total time the key has been turned to “ON”) Odometer and tripmeter modes Pushing the “TRIP/ODO” button switches the dis- play between the odometer mode “ODO” and the tripmeter modes “A” and “B” in the following order: ODO →...

  • Page 28: Fuel Gauge

    To set the clock 1. Set the display to the clock mode. If the ATV runs out of fuel, move the fuel cock lever 2. Push the “ / ” button until the clock starts to the “RES” position. Approximately 4.5 L (1.19 flashing.
  • Page 29 EBU18080 ECB00040 Engine stop switch “ ” NOTICE Set this switch to “ ” before starting the engine. Do not use the headlights with the engine The engine stop switch controls the ignition and turned off for an extended period of time, oth- stops the engine when it is running.
  • Page 30 In limiting function. (See page 4-8.) Releasing the this case, take the ATV to a Yamaha dealer at the switch restores the speed limiting function. first opportunity.
  • Page 31 “2WD” (two-wheel drive): Power is supplied to EWB00163 WARNING the rear wheels. “4WD” (four-wheel drive): Power is supplied to Always stop the ATV before changing from the rear and front wheels. two-wheel drive to four-wheel drive and vice To change from two-wheel drive to four-wheel versa.
  • Page 32 1. On-Command four-wheel-drive switch “2WD”/“4WD” 1. Differential gear lock lever 2. On-Command differential gear lock switch “4WD”/“LOCK” 2. On-Command four-wheel-drive switch “2WD”/“4WD” To lock the differential gear in four-wheel drive, Stop the ATV, move the differential gear lock lever make sure the On-Command four-wheel-drive to position (a), and then push the differential gear switch is pushed in to the “4WD”...
  • Page 33 pectedly. This could distract the operator and increase the risk of losing control and causing an accident. EWB00140 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 dif- ferential gear is locked, so it takes more effort to turn the ATV.

  • Page 34: Throttle Lever

    This could cause an accident. Check the op- the throttle lever. eration of the throttle lever before you start the engine. If the throttle does not work smoothly, check for the cause. Correct the problem be- fore riding the ATV or consult a Yamaha dealer. 4-11...

  • Page 35: Speed Limiter

    EBU18321 3. Tighten the locknut. Speed limiter EWB00240 Your ATV was delivered with an adjustable speed WARNING limiter. The speed limiter keeps the throttle from Improper adjustment of the speed limiter and fully opening, even when the throttle lever is throttle could cause throttle cable damage or pushed to the maximum.

  • Page 36: Brake Pedal And Rear Brake Lever

    1. Front brake lever 1. Brake pedal EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.

  • Page 37: Drive Select Lever

    EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. 1.

  • Page 38: Fuel

    1. Fuel level 1. Fuel tank cap 2. Fuel tank filler tube EBU18752 Fuel Recommended fuel: Make sure that there is sufficient fuel in the tank. UNLEADED GASOLINE ONLY Fill the fuel tank to the bottom of the filler tube as For Europe: Regular unleaded gasoline only shown.

  • Page 39: Fuel Cock

    EBU18820 Fuel cock If knocking or pinging occurs, use a different brand The fuel cock supplies fuel from the tank to the car- of gasoline or higher octane grade. buretor while also filtering it. The fuel cock lever positions are explained as fol- ECB00070 lows and shown in the illustrations.

  • Page 40: Starter (Choke)

    1. Arrow mark pointing to “ON” 1. Arrow mark pointing to “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.

  • Page 41: Seat

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Seat 2. Seat lock lever To install the seat Insert the projections on the front of the seat into 1.

  • Page 42: Storage Compartments

    1. Front storage compartment cover 1. Projection 2. Seat holder EBU29251 Storage compartments This ATV is equipped with two storage compart- ments. 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.
  • Page 43 The rear storage compartment is located under the ECB00830 NOTICE seat. (See page 4-18.) 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 stor- age compartments.

  • Page 44: Front Carrier

    EBU18961 Front carrier Do not exceed the load limit of 40.0 kg (88 lb) for the front carrier. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. EBU18971 Rear carrier Do not exceed the load limit of 80.0 kg (176 lb) for the rear carrier.
  • Page 45 1. Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: Maximum (hard): 4-22...

  • Page 46: Auxiliary Dc Jack

    EWB00400 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 ac- cident. EBU19181 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV.
  • Page 47 If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine start- ing 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.

  • Page 48: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 49 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-4, 8-39, 8-40, 8-41 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 50: Fuel

    EBU19540 EBU19600 Fuel Differential gear oil Make sure that there is sufficient fuel in the tank. Make sure that the differential gear oil is at the (See page 4-15.) specified level. Add oil as necessary. (See page EWB00520 8-25.) WARNING EBU19630 Do not overfill the fuel tank.

  • Page 51: Front And Rear Brakes

    Brake levers and brake pedal Check that there is no free play in the front brake Brake operation lever. If there is free play, have a Yamaha dealer Test the brakes at slow speed after starting out to check the brake system.

  • Page 52: Tires

    25.0 kPa (0.250 kgf/cm², 3.6 psi) The tires listed below have been approved • Check and adjust tire pressures when the by Yamaha Motor Manufacturing Corpora- tires are cold. tion of America for this model. Other tire • Tire pressures must be equal on both combinations are not recommended.

  • Page 53: Measuring The Tire Pressure

    Rear: 250 kPa (2.5 kgf/cm², 36 psi) Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully. EBU19821 Measuring the tire pressure Use the low-pressure tire gauge. The low-pressure tire gauge is included as stan- 1.

  • Page 54: Tire Wear Limit

    EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly.

  • Page 55: Operation

    The corresponding indicator accident or injury. If there is a control or func- light should come on. If the indicator light does tion you do not understand, ask your Yamaha not come on, have a Yamaha dealer check dealer.
  • Page 56 4. Use the starter (choke) in reference to the fig- 5. Apply the rear brake lever. ure: 6. Completely close the throttle lever and start Position (1): the engine by pushing the start switch. Cold engine start with ambient temperature below 5 °C (40 °F).

  • Page 57: Starting A Warm Engine

    8. Continue warming up the engine until it idles 2. Apply the brake pedal, and then shift by mov- smoothly, then return the starter (choke) to ing the drive select lever along the shift guide. position (3) before riding. Make sure that the drive select lever is completely The engine is warm when it responds normally to shifted into position.
  • Page 58 6. P (Park) When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the elec- trical circuit. Due to the synchronizing mechanism in the en- gine, the indicator light may not come on until the...

  • Page 59: Engine Break-In

    There is never a more important period in the life of engine break-in period, immediately have a your engine than the first 320 km (200 mi) or 20 Yamaha dealer check the ATV. hours of riding. For this reason, you should read the following material carefully.

  • Page 60: Parking

    However, 3. With the brake pedal applied, shift the drive it is not possible for Yamaha to test all non- select lever to the park position. Yamaha accessories, nor control over their qual-...
  • Page 61 Choose a genuine Yamaha ac- MAXIMUM LOADING LIMIT cessory, or one that is equivalent in design and ATV loading limit (total weight of rider, cargo, quality. accessories, and tongue): Accessories should be rigidly and securely 210.0 kg (463 lb) mounted.
  • Page 62 the weight on the hitch. If you are carrying cargo EWB00820 WARNING and towing a trailer, include the tongue weight in the maximum ATV load limit. Never exceed the stated load capacity for this Load cargo on the carriers as close to the center ATV.

  • Page 63: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 64: Getting To Know Your Atv

    EBU29231 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV Beginners should get training from a certified in- This ATV is for recreation and utility use. This sec- structor. tion, Riding your ATV, provides general ATV riding Become familiar with this ATV at slow speeds first, instructions for recreational riding.
  • Page 65 Not recommended for children under 16 years This ATV is designed to carry operator and car- of age. go only – passengers prohibited. EWB01390 EWB01400 WARNING WARNING A child under 16 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 90 cc.
  • Page 66 Apparel Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet...
  • Page 67 EWB01410 WARNING Never operate this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 68 in the Owner’s Manual. Failure to inspect the Speed limiter ATV before operating or failure to properly For riders less experienced with this model, the maintain the ATV increases the possibility of throttle lever housing is equipped with a speed lim- an accident or equipment damage.
  • Page 69 Loading and accessories EWB01460 WARNING Use extra caution when riding the ATV with addi- tional loads, such as accessories or cargo. The Never exceed the stated load capacity for ATV’s handling may be adversely affected. Re- this ATV. duce your speed when adding additional loads. Cargo should be properly distributed and se- curely attached.
  • Page 70 All parts and tact with the rear wheels, which could injure accessories added to this ATV should be gen- you or cause an accident. uine Yamaha or equivalent components de- signed for use on this ATV and should be...

  • Page 71: Be Careful Where You Ride

    installed and used according to instructions. Improper installation of accessories or modifi- cation of this ATV may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized ATV dealer. Exhaust system The exhaust system on the ATV is very hot during and following operation.
  • Page 72 EWB01520 WARNING Never operate this ATV on any paved street, paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. While riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles.
  • Page 73 EWB01530 ATV on such terrain. Failure to use extra care WARNING when operating on excessively rough, slippery or loose terrain could cause loss of traction or Go slowly and be extra careful when operating ATV control, which could result in an accident, on unfamiliar terrain.
  • Page 74 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice EWB01550 control of the throttle, brakes, shifting procedures, WARNING and turning techniques in this area before trying Always mount a caution flag on the ATV to more difficult terrain.

  • Page 75: Turning Your Atv

    With the engine idling, shift the drive select lever wheels also turn together at the same speed. into the low-range position or the high-range posi- Therefore, unless the wheel on the inside of the tion. Apply the throttle slowly and smoothly. The turn is allowed to slip or lose some traction, the centrifugal clutch will engage and you will start to ATV will resist turning.

  • Page 76: Climbing Uphill

    Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.
  • Page 77 EWB01580 Never go over the top of any hill at high WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never operate the ATV on hills too steep for the of the hill. ATV or for your abilities.
  • Page 78 EWB01600 WARNING Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique 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.

  • Page 79: Riding Downhill

    could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediate- ly on the uphill side. EWB01781 WARNING Use the proper gear and maintain a steady speed when climbing a hill.

  • Page 80: Crossing A Slope

    When this ATV is in 4WD or 4WD-LOCK, all Avoid going down a hill at an angle that wheels (front and rear) are interconnected by the would cause the ATV to lean sharply to one drive train. This means that applying either the side.

  • Page 81: Crossing Through Shallow Water

    to cross a sloping surface. Avoid slopes with slip- Shift your weight to the uphill side of the pery surfaces or rough terrain that may upset your ATV. balance. As you travel across a slope, lean your body in the uphill direction.
  • Page 82 EWB01640 Test your brakes after leaving the water. Do not WARNING continue to ride your ATV without verifying that you have regained proper braking ability. Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual.
  • Page 83 cumulated. Wash the ATV in fresh water if it has been operated in salt water or muddy con- ditions. 1. V-belt cooling duct check hose (left front side of ATV) 1. Air filter case check hose 1. Drive select lever box check hose 7-21...

  • Page 84: Riding Over Rough Terrain

    1. Storage compartment check hose 1. Storage compartment drain plug RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident.

  • Page 85: Sliding And Skidding

    you go over obstacles, always follow proper If the rear wheels of your ATV start to slide side- procedures as described in the Owner’s Manu- ways, control can usually be regained (if there is room to do so) by steering in the direction of the slide.

  • Page 86: What To Do If

    EWB01661 If your ATV starts to slide sideways: WARNING Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not Learn to safely control skidding or sliding by recommended until you have corrected the practicing at low speeds and on level, smooth terrain.
  • Page 87 BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-19.) 7-25...

  • Page 88: Periodic Maintenance And Minor Repair

    EBU28782 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21670 otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with Safety is an obligation of the owner. Periodic in- maintenance work. spection, adjustment and lubrication will keep your...
  • Page 89 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING...

  • Page 90: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 92: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
  • Page 93 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Drive shaft univer- √ √ √ • Lubricate with lithium-soap-based grease. sal joint • Make sure that all nuts, bolts, and screws are √...
  • Page 94 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Change. √ √ √ Final gear oil • Check ATV for oil leakage, and correct if neces- sary.
  • Page 95 Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.

  • Page 96: Removing And Installing Panels

    EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel C 2.
  • Page 97 To install one of the panels 1. Place the panel in its original position. 8-10...
  • Page 98 Panel B To remove the panel Remove the bolt, and then take the panel off. 1. Panel B 2. Bolt To install the panel Place the panel in the original position and install the bolt. ECB00380 NOTICE When installing the panel, be sure not to pinch 2.
  • Page 99 Panel C To remove the panel 1. Remove the carrier top bolts. 1. Carrier bolt (under the fenders) 3. Remove the quick fastener screws, and then pull the panel upward to remove it. 1. Carrier bolt (top) 2. Remove the carrier bolts under the fenders, and then take the carrier off.
  • Page 100 Tightening torques: Carrier bolt (top): 34 Nm (3.4 m·kgf, 24 ft·lbf) Carrier bolt (under fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Panel E To remove the panel Remove the bolts, and then take the panel off. 1. Quick fastener screw 2.

  • Page 101: Checking The Spark Plug

    To install the panel Place the panel in the original position and install the bolts. Panel F To remove the panel Pull outward on the areas shown. EBU23221 Checking the spark plug The spark plug is an important engine component, which is easy to check.
  • Page 102 (the ideal color when the ATV is ridden normally). If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-15...
  • Page 103 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DR8EA To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

  • Page 104: Engine Oil And Oil Filter Cartridge

    If a torque wrench is not available when installing If the engine was started before checking the oil a spark plug, a good estimate of the correct torque level, be sure to warm up the engine sufficiently, is 1/4–1/2 turn past finger tight. However, the spark and then wait at least ten minutes until the oil set- plug should be tightened to the specified torque as tles for an accurate reading.
  • Page 105 To change the engine oil (with or without oil fil- ter cartridge replacement) 1. Place the ATV on a level surface. 2. Remove panel F. (See page 8-9.) 3. Start the engine, warm it up for several min- utes, and then turn it off. 4.
  • Page 106 7. Remove the oil filter cartridge with an oil filter wrench. 1. Oil filter wrench An oil filter wrench is available at a nearby Yamaha dealer. 8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
  • Page 107 1. O-ring 1. Torque wrench Tightening torque: Oil filter cartridge: Make sure that the O-ring is properly seated. 17 Nm (1.7 m·kgf, 12 ft·lbf) 9. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to the specified 10.
  • Page 108 12. Refill with the specified amount of the recom- Make sure that no foreign material enters the mended engine oil, and then install and tight- crankcase. en the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.43 US qt, 2.02 Imp.qt) With oil filter cartridge replacement: 2.40 L (2.54 US qt, 2.11 Imp.qt)

  • Page 109: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, 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.
  • Page 110 2. Remove the engine guard and the final gear case guard by removing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the 1. Engine guard specified torque. 2. Final gear case guard 3.
  • Page 111 ECB00420 NOTICE Be sure no foreign material enters the final gear case. 7. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 24 Nm (2.4 m·kgf, 17 ft·lbf) 1. Final gear oil filler bolt 8.

  • Page 112: Differential Gear Oil

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil level must be checked and the oil changed as follows at the in- tervals specified in the periodic maintenance and lubrication chart.
  • Page 113 To change the differential gear oil 5. Refill with the recommended differential gear 1. Place the ATV on a level surface. oil to the brim of the filler hole as shown. 2. Place an oil pan under the differential gear case to collect the used oil.

  • Page 114: Coolant

    Tightening torque: Differential gear oil filler bolt: The coolant should be between the minimum and 23 Nm (2.3 m·kgf, 17 ft·lbf) maximum level marks. 7. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23470 Coolant The coolant level should be checked before each...
  • Page 115 If water has been added to the coolant, have from spilling on the footrest.) a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- erwise the effectiveness of the coolant will be reduced.
  • Page 116 4. Remove the front carrier and panel C. (See page 8-9.) 5. Remove the radiator cap. 1. Coolant drain bolt 1. Radiator cap 6. Remove panel D. (See page 8-9.) 7. Remove the coolant reservoir cap. 8. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the cool- ant reservoir.
  • Page 117 13. Pour the recommended coolant into the radia- tor until it is full. Antifreeze/water mixture ratio: Recommended antifreeze: High-quality ethylene glycol antifreeze con- taining corrosion inhibitors for aluminum en- gines Coolant quantity: Radiator capacity (including all routes): 1.30 L (1.37 US qt, 1.14 Imp.qt) 1.

  • Page 118: Cleaning The Air Filter Element

    16. Start the engine, and then check for coolant leakage. If any leakage is found, have a Yamaha dealer check the cooling system. 1. Air filter case check hose 17. Install the panels and the front carrier.
  • Page 119 1. Air filter case cover holder 1. Air filter element 2. Air filter case cover 5. Pull off the air filter element lock plate, and 4. Pull the air filter element out of the air filter then remove the sponge material from the air case.
  • Page 120 ECB00440 NOTICE Do not twist the sponge material when squeez- ing it. 1. Air filter element frame 2. Sponge material 3. Air filter element lock plate 6. Wash the sponge material gently but thor- oughly in solvent. 8. Check the sponge material and replace it if EWB01940 damaged.

  • Page 121: Cleaning The Spark Arrester

    11. Insert the air filter element into the air filter will affect carburetor jetting with subsequent case, and then install the air filter case cover poor performance and possible engine over- by hooking the holders onto the air filter case. heating.

  • Page 122: V-Belt Cooling Duct Check Hose

    3. Tap the tailpipe lightly, and then use a wire EWB02340 WARNING brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside Do not start the engine when cleaning the of the tailpipe housing. spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire.

  • Page 123: V-Belt Case Drain Plug

    If water drains from the V-belt case after removing most carburetor adjustments should be left to a the plug, have a Yamaha dealer check the ATV as Yamaha dealer, who has the necessary profes- the water may affect other engine parts.
  • Page 124 1450–1550 r/min tle stop screw in direction (a), and to decrease it, turn the screw in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 5. Install the panel. 8-37...

  • Page 125: Adjusting The Throttle Cable Free Play

    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 the periodic maintenance and lu- brication chart.

  • Page 126: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm es with use, which can result in improper function. (0.04 in), have a Yamaha dealer replace the brake Therefore, the safety system cable should be pads as a set.

  • Page 127: Checking The Brake Fluid Level

    A low brake fluid level may indicate worn the wear indicator reaches the wear limit mark, brake pads and/or brake system leakage. If the have a Yamaha dealer replace the brake friction brake fluid level is low, be sure to check the brake plates as a set.

  • Page 128: Changing The Brake Fluid

    Yamaha dealer check the cause. EBU24281 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic 1. Brake lever free play maintenance and lubrication chart. In addition,...

  • Page 129: Adjusting The Brake Pedal And Rear Brake Lever Free Play And Checking The Brake Pedal Position

    Replacement of brake components requires play professional knowledge. These procedures The brake pedal free play should measure 17.0– should be performed by a Yamaha dealer. 20.0 mm (0.67–0.79 in). The brake lever free play should measure 8.0–10.5 mm (0.31–0.41 in). If ei- EBU28635 ther free play is incorrect, adjust it as follows.
  • Page 130 1. Brake pedal free play 1. Locknut 2. Brake lever free play adjusting bolt 2. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the final gear case. 1. Brake lever free play 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt.
  • Page 131 1. Brake lever free play adjusting nut 1. Brake pedal free play adjusting nut 2. Brake camshaft lever 3. Push the brake camshaft lever in direction (a) 3. Gap “A” until it stops [apply approximately 50 N (5.0 4. Push the brake camshaft lever in direction (a) kgf, 11.0 lbf) of force], and then turn the brake until it stops [apply approximately 50 N (5.0 pedal free play adjusting nut on the brake ca-...
  • Page 132 (a) to increase the free play, and in direction (b) to decrease it. Checking the brake pedal position The top of the brake pedal should be positioned 75.0–85.0 mm (2.95–3.35 in) above the footboard. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 8-45...

  • Page 133: Axle Boots

    1. Front axle boot (each side) Make sure the brakes operate smoothly and that the free play is correct. Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 8-46...

  • Page 134: Brake Light Switches

    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. 1. Remove panel B. (See page 8-9.) 1. Brake light switch 2. Brake light switch adjusting nut 3.

  • Page 135: Checking And Lubricating The Cables

    Rear brake lever: cables and cable ends should be lubricated if nec- Lithium-soap-based grease essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil EWB02130 WARNING Inspect cables frequently and replace if dam- aged.

  • Page 136: Checking The Wheel Hub Bearings

    Yamaha dealer check the wheel hub bear- To access the brake pedal pivot, remove panel B. ings. (See page 8-9.) EBU24970 Lubricating the drive shaft universal...

  • Page 137: Lubricating The Rear Knuckle Pivots

    EBU25051 EBU25102 Lubricating the rear knuckle pivots Lubricating the steering shaft The rear knuckle pivots must be lubricated at the The steering shaft must be lubricated at the inter- intervals specified in the periodic maintenance and vals specified in the periodic maintenance and lu- lubrication chart.
  • Page 138 4. Pull the battery out of its compartment. To charge the battery To remove the battery Have a Yamaha dealer charge the battery as soon 1. Remove the seat. (See page 4-18.) as possible if it seems to have discharged. Keep in 2.

  • Page 139: Replacing A Fuse

    Using a conventional bat- tery charger will damage the battery. If you do not have access to a constant-voltage battery charger, have a Yamaha dealer charge your battery. To store the battery 1. Positive battery lead (red) If the ATV will not be used for more than one 2.
  • Page 140 1. Main fuse 1. Headlight fuse 2. Fuse box 2. Ignition fuse 3. Auxiliary DC jack fuse 4. Four-wheel-drive motor fuse 5. Signaling system fuse 6. Backup fuse (for odometer and clock) 7. Spare fuse If a fuse is blown, replace it as follows. 1.

  • Page 141: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical new fuse of the specified amperage. circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Specified fuses: Yamaha dealer check the electrical system. Main fuse: EBU25480 30.0 A Replacing a headlight bulb Headlight fuse: If a headlight bulb burns out, replace it as follows.
  • Page 142 4. Remove the defective bulb by pulling it out. EWB02220 WARNING A headlight bulb is hot when it is on and imme- diately after it is turned off. Wait for the bulb to cool before touching or removing it. You can be burned or a fire could start if the bulb touch- es something flammable.

  • Page 143: Adjusting A Headlight Beam

    8. Adjust the headlight beam if necessary. follows. 1. Remove the tail/brake light assembly by re- EBU25551 Adjusting a headlight beam moving the nuts together with the washers. ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. 8-56...
  • Page 144 1. Tail/brake light assembly 1. Tail/brake light assembly 2. Nut 2. Tail/brake light bulb holder 2. Remove the bulb holder (together with the 3. Remove the defective bulb by pushing it in bulb) by turning it counterclockwise. and turning it counterclockwise. 8-57...

  • Page 145: Removing A Wheel

    1. Tail/brake light bulb holder 1. Wheel nut 2. Tail/brake light bulb 3. Elevate the ATV and place a suitable stand 4. Insert a new bulb into the bulb holder, push it under the frame. in, and then turn it clockwise until it stops. 4.
  • Page 146 Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Tapered nut 3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified torques.

  • Page 147: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 148: Troubleshooting Charts

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.
  • Page 149 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.

  • Page 150: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25880 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 151: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the brakes after washing. Apply the brakes several 2.
  • Page 152 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-50.

  • Page 153: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 1991 mm (78.4 in) Liquid cooled 4-stroke, SOHC Overall width: Cylinder arrangement: 1093 mm (43.0 in) Forward-inclined single cylinder Overall height: Displacement: 1120 mm (44.1 in) 421.0 cm³ Bore × stroke: Seat height: 84.5 ×...
  • Page 154 Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: ACC-SHAFT-LU-00) or SAE 80 API GL-4 Hypoid gear oil 50 ˚C (AUS)(NZL) Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 SAE 5W-30 API GL-4 Hypoid gear oil (EUR) Quantity: SAE 10W-30 0.23 L (0.24 US qt, 0.20 Imp.qt)
  • Page 155 Type × quantity: Caster angle: BSR33 x 1 2.5 ° Spark plug (s): Trail: 8.5 mm (0.33 in) Manufacturer/model: Front tire: NGK/DR8EA Spark plug gap: Type: 0.6–0.7 mm (0.024–0.028 in) Tubeless Clutch: Size: AT25 x 8-12 Clutch type: Manufacturer/model: Wet, centrifugal automatic CHENG SHIN/C-828 (AUS)(NZL) Transmission: MAXXIS/M979 (EUR)
  • Page 156 Minimum: Spring/shock absorber type: Front: Coil spring/oil damper 22.0 kPa (0.220 kgf/cm², 3.2 psi) Wheel travel: Rear: 160 mm (6.3 in) 22.0 kPa (0.220 kgf/cm², 3.2 psi) Rear suspension: Front wheel: Type: Wheel type: Double wishbone Panel wheel Spring/shock absorber type: Rim size: Coil spring/oil damper 12 x 6.0AT...
  • Page 157 Reverse indicator light: Coolant temperature warning light: Park indicator light: On-Command four-wheel-drive/differential gear lock indicator: High-range indicator light: Low-range indicator light: Differential gear lock indicator light: Fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Ignition fuse: 10.0 A Auxiliary DC jack fuse:...

  • Page 158: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 159 EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 160 1. Model label 11-3...
  • Page 161 INDEX Accessories and loading ..........6-6 Differential gear lock indicator light ........ 4-3 Accessories, auxiliary jack ........... 4-23 Differential gear oil ..........5-3, 8-25 Air filter element, cleaning ..........8-31 Drive select lever ............4-14 Axle boots ..............8-46 Drive select lever and driving in reverse ......6-3 Drive select lever safety system cable, adjusting ..
  • Page 162 Horn switch ..............4-6 Rear knuckle pivots, lubricating ........8-50 Identification numbers ..........11-1 Recoil starter ..............4-14 Indicator lights and warning light ........4-2 Reverse indicator light ............ 4-2 Instruments, lights and switches ........5-7 Riding your ATV ............. 7-1 Key identification number ..........
  • Page 163 V-belt cooling duct check hose ........8-35 Vehicle identification number ........11-1 Wheel hub bearings, checking ........8-49 Wheel, installing ............8-58 Wheel, removing ............8-58...
  • Page 164 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2008.06-0.9×1 CR...

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