yamaha kodiak 450 lit-11626-18-35_972

1D9-F8199-10LIT-11626-18-35

READ THIS MANUAL CAREFULLY!It contains important safety information.

This ATV should not be ridden by anyone under 16 years of age.WARNING

YFM450FAT

OWNER’S MANUAL

PRINTED IN USA2004.06-4.4×1 CR

(E)

YAMAHA MOTOR CO., LTD.

EBU00438

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-pavement may seriously affect handling and control.

Improper ATV use can result in SEVERE INJURY or DEATH.

NEVER operate: without proper training or instruction. at speeds too fast for your skills or the conditions. on public roads-a collision can occur with another vehicle. with a passenger-passengers affect balance and steering and increase risk of losing control.

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

B EE R

B EE R

EBU00776

EBU00941

1-INTRODUCTION

Congratulations on your purchase of the Yamaha YFM450FA. It represents the result of manyyears of Yamaha experience in the production of fine sporting, touring, and pace-setting racingmachines. With the purchase of this Yamaha, you can now appreciate the high degree of crafts-manship and reliability that have made Yamaha a leader in these fields.This manual will provide you with a good basic understanding of the features and operation of thisATV. This manual includes important safety information. It provides information aboutspecial techniques and skills necessary to ride your ATV. It also includes basic maintenanceand inspection procedures. If you have any questions regarding the operation or maintenance ofyour ATV, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:� READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND

COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALLINSTRUCTIONS.

� PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.� NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE

TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887FOR MORE INFORMATION.

� THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONEUNDER 16 YEARS OF AGE.

U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM

EBU00801

ON

UAL CAN RESULT IN SE-

following notations:

ION! BECOME ALERT!

could result in severe bystander or a person

that must be taken to

cedures easier or clearer.


IMPORTANT MANUAL INFORMATI

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANRIOUS INJURY OR DEATH.Particularly important information is distinguished in this manual by the

The Safety Alert Symbol means ATTENTYOUR SAFETY IS INVOLVED!

WARNING Failure to follow WARNING instructions injury or death to the machine operator, ainspecting or repairing the machine.

CAUTION: A CAUTION indicates special precautionsavoid damage to the machine.

NOTE: A NOTE provides key information to make pro

is illegal and unsafe to oper-

park arrester laws and regu-

g this ATV.

YFM450FATER’S MANUAL aha Motor Corporation,

U.S.A. dition, May 2004erved. Any reprinting or

unauthorized use without the written permission of

Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in U.S.A. P/N LIT-11626-18-35


AFFIX DEAL

LABEL HER

EBU15000

This ATV is designed and mate this ATV on any public This ATV complies with alllations in effect at the time Please check your local rid

EBU01067

ER

E

1-IMPORTANT NOTICE

anufactured for OFF-ROAD use only. Itstreet, road or highway. applicable OFF-ROAD noise level and sof manufacture.ing laws and regulations before operatin

OWN©2004 by Yam

1st eAll rights res

EBU00014

Key identificationVehicle identificaModel label ........

CONTROL FUNCMain switch........

4

warning lights.............4-2......................................4-4r unit ............................4-5

witches .........................4-7r ..................................4-13r ..................................4-14ever............................4-15and rear brake ....................................4-15lever ...........................4-16r..................................4-17p .................................4-18....................................4-18e) ..............................4-20

....................................4-20partment ....................4-21...................................4-22....................................4-22ar shock absorber ...................................4-23 jack............................4-25


number................ 3-2tion number .......... 3-3.............................. 3-3

TIONS .................. 4-1.............................. 4-1

Rear carrierFront and readjustment

Auxiliary DC

WARNINGIndicates a potential hazard that couldresult in serious injury or death.

CONTENTS

LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1

SAFETY INFORMATION.................. 2-1

DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1Identification number records.......... 3-2

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2

3

Indicator andFuel gauge .SpeedometeHandlebar sThrottle leveSpeed limiteFront brake lBrake pedal lever .........

Drive select Recoil starteFuel tank caFuel cock....Starter (chokSeat............Storage comFront carrier

a slope...........................6-9 and loading ...............6-10

R ATV..........................7-1now your ATV ...............7-3re and good ......................................7-4here you ride..............7-16r ATV ..........................7-22hill ...............................7-24hill ..............................7-30

slope............................7-32rough shallow water ....7-34 rough terrain...............7-37skidding.......................7-38if ..................................7-40....................................7-40


PRE-OPERATION CHECKS ........... 5-1Front and rear brakes ..................... 5-2Fuel ................................................. 5-4Engine oil ........................................ 5-6Final gear oil.................................... 5-6Differential gear oil .......................... 5-6Coolant............................................ 5-7Throttle lever ................................... 5-7Fittings and fasteners...................... 5-8Lights............................................... 5-8Switches.......................................... 5-8Tires ................................................ 5-8How to measure tire pressure....... 5-10Tire wear limit................................ 5-11

OPERATION..................................... 6-1Starting a cold engine ..................... 6-1Starting a warm engine................... 6-3Warming up..................................... 6-3Drive select lever operation and reverse driving............................... 6-4

Engine break-in............................... 6-7Parking ............................................ 6-8

Parking on Accessories

RIDING YOUGetting to kRide with cajudgement

Be careful wTurning youClimbing upRiding downCrossing a Crossing thRiding overSliding and What to do What to do

5

6

7

ad check...................8-39ad check....................8-40e brake fluid level ......8-41placement .................8-42ever free play.............8-43 rear brake lever and l ..................................8-44 rear brake light

....................................8-46tion and

....................................8-47he brake levers and l ..................................8-47 upper and lower tion ............................8-48

val...............................8-49lation...........................8-49....................................8-50tenance......................8-52ment ..........................8-52headlight bulb ............8-54am adjustment...........8-57


PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1Owner’s manual and tool kit............ 8-1Periodic maintenance/lubrication ...................................... 8-3

Panel removal and installation ........ 8-6Engine oil and oil filter cartridge .... 8-12Final gear oil .................................. 8-17Differential gear oil......................... 8-20Cooling system.............................. 8-22Changing the coolant .................... 8-24Axle boots...................................... 8-27Spark plug inspection.................... 8-28Air filter element cleaning.............. 8-31V-belt cooling duct check hose ..... 8-34V-belt case drain plug.................... 8-34Spark arrester cleaning ................. 8-35Carburetor adjustment................... 8-36Idle speed adjustment ................... 8-37Valve clearance adjustment.......... 8-38Throttle lever adjustment............... 8-38Select lever safety system cable adjustment ......................... 8-39

Front brake pRear brake pInspecting thBrake fluid reFront brake lAdjusting thebrake peda

Adjusting theswitch .......

Cable inspeclubrication.

Lubricating tbrake peda

Rear knucklepivot lubrica

Wheel remoWheel instalBattery........Battery mainFuse replaceReplacing a Headlight be

8


Tail/brake light bulb replacement ................................ 8-58

Troubleshooting ............................ 8-59Troubleshooting charts ................. 8-61

CLEANING AND STORAGE............ 9-1A. Cleaning...................................... 9-1B. Storage ....................................... 9-3

SPECIFICATIONS.......................... 10-1

NOISE REGULATION.................... 11-1

MAINTENANCE RECORD ............ 12-1

ATV LIMITED WARRANTY............ 13-1

YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................... 14-1

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D


1-1

1-LOCATION OF THE WARNING ANSPECIFICATION LABELS

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rrying cargo improperly can changeking performance and can lead to ane maximum front cargo limit of

Refer to instructions in the Owner's

5ND-F4877-00

ARNING


1-2

Read and understand all of the labels on yourmachine. They contain important informationfor safe and proper operation of your ATV.

Never remove any labels from your ATV. If alabel becomes difficult to read or comes off, areplacement label is available from yourYamaha dealer.

3

1

2

Overloading this ATV or cahandling, stability and braaccident. Never exceed th : 40kg (88 lbs)NEVER sit on the carr ier. Manual.

W


1-3

33 l b f5ND-F151K-00

4

5

Overloading this ATV or carrying cargo improperly can changehandling, stability and braking performance and can lead to anaccident. Never exceed the maximum rear cargo limit of : 80kg (176 lbs)NEVER sit on the carr ier. Refer to instructions in the Owner'sManual.

5ND-F4897-00

WARNING

PULLING LOAD: 4900 N ( 5 0 0 k g f )1102 l b f

TONGUE WEIGHT: 147 N ( 1 5 k g f )

MAXIMUM.LOADING LIMITMAXIMUM LOADING LIMIT

6

D-LOCK(“DIFF. LOCK” )

ed and allow

e for maneuvers

l.

5ND-F1558-00

NING


1-4

7 8

9

UNDER

WARNING

YAMAHA 4XE-F415A-00

NEVER operate this ATV if you areunder age 16.

Operating this ATV if you are underthe age of 16 increases your chanceof severe injury or death.

Turning the ATV in 4W

takes more effort.

Operate at a slow spe

extra time and distanc

to avoid loss of contro

WAR

EBU13351

An ATV handles differentlyer can occur quickly, evenbstacles, if you fail to take

tructions: rocedures described. Training Course. Begin-thorized ATV dealer or call

ne size greater than 90cc. pervision, and never allowbilities to operate it safely.

idewalks, driveways, park-

a dirt or gravel one.


2-1

SAFETY INFORMATION

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. from other vehicles including motorcycles and cars. A collision or rollovduring routine maneuvers such as turning and riding on hills or over oproper precautions. SEVERE INJURY OR DEATH can result if you do not follow these ins� Read this manual and all labels carefully and follow the operating p� Never operate an ATV without proper training or instruction. Take a

ners should receive training from a certified instructor. Contact an au1-800-887-2887 to find out about the training courses nearest you.

� Always follow the age recommendation: – A child under 16 years old should never operate an ATV with engi

� Never allow a child under age 16 to operate an ATV without adult sucontinued use of an ATV by a child if he or she does not have the a

� Never carry a passenger on an ATV. � Always avoid operating an ATV on any paved surfaces, including s

ing lots and streets. � Never operate an ATV on any public street, road or highway, even

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lmet that fits properly. Youots, a long-sleeved shirt or

. lways go at a speed that isrience.

afe operating condition. Al-ules described in this man-

otboards of the ATV during

r terrain. Always be alert to

you have learned and prac-s be especially cautious on

nual. Practice turning at lowxcessive speed. bilities. Practice on smaller


2-2

� Never operate an ATV without wearing an approved motorcycle heshould also wear eye protection (goggles or face shield), gloves, bojacket, and long pants.

� Never consume alcohol or drugs before or while operating this ATV� Never operate at speeds too fast for your skills or the conditions. A

proper for the terrain, visibility, operating conditions, and your expe� Never attempt wheelies, jumps, or other stunts. � Always inspect your ATV each time you use it to make sure it is in s

ways follow the inspection and maintenance procedures and schedual.

� Always keep both hands on the handlebars and both feet on the fooperation.

� Always go slowly and be extra careful when operating on unfamiliachanging terrain conditions when operating the ATV.

� Never operate on excessively rough, slippery or loose terrain until ticed the skills necessary to control the ATV on such terrain. Alwaythese kinds of terrain.

� Always follow proper procedures for turning as described in this maspeeds before attempting to turn at faster speeds. Do not turn at e

� Never operate the ATV on hills too steep for the ATV or for your ahills before attempting larger hills.

his manual. Check the ter-cessively slippery or loosenly or make sudden gear

ng on hills as described inill. Shift your weight back-

an angle that would causeere possible. described in this manual.ight to the uphill side of theave mastered the turning

g the side of a steep hill if

mbing a hill. To avoid stall-ing a hill. If you stall or rolls manual. Dismount on theand remount, following the

r attempt to operate overoper procedures when op-


2-3

� Always follow proper procedures for climbing hills as described in train carefully before you start up any hill. Never climb hills with exsurfaces. Shift your weight forward. Never open the throttle suddechanges. Never go over the top of a hill at high speed.

� Always follow proper procedures for going down hills and for brakithis manual. Check the terrain carefully before you start down any hward. Never go down a hill at high speed. Avoid going down a hill atthe vehicle to lean sharply to one side. Go straight down the hill wh

� Always follow proper procedures for crossing the side of a hill asAvoid hills with excessively slippery or loose surfaces. Shift your weATV. Never attempt to turn the ATV around on any hill until you htechnique described in this manual on level ground. Avoid crossinpossible.

� Always use proper procedures if you stall or roll backwards when cliing, use the proper gear and maintain a steady speed when climbbackwards, follow the special procedure for braking described in thiuphill side or to a side if pointed straight uphill. Turn the ATV around procedure described in this manual.

� Always check for obstacles before operating in a new area. Nevelarge obstacles, such as large rocks or fallen trees. Always follow prerating over obstacles as described in this manual.

skidding or sliding by prac-pery surfaces, such as ice,idding or sliding out of con-

n that recommended in thisbility. Test your brakes afterdry out the linings. en you operate in reverse.

sories. be properly distributed andanual for carrying cargo or

mer Products Safety Com- 1-800-852-5344.


2-4

� Always be careful when skidding or sliding. Learn to safely controlticing at low speeds and on level, smooth terrain. On extremely slipgo slowly and be very cautious in order to reduce the chance of sktrol.

� Never operate an ATV in fast flowing water or in water deeper thamanual. Remember that wet brakes may have reduced stopping aleaving water. If necessary, apply them several times to let friction

� Always be sure there are no obstacles or people behind you whWhen it is safe to proceed in reverse, go slowly.

� Always use the size and type of tires specified in this manual. � Always maintain proper tire pressure as described in this manual. � Never modify an ATV through improper installation or use of acces� Never exceed the stated load capacity for an ATV. Cargo should

securely attached. Reduce speed and follow instructions in this mpulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at

ng the ATV in another it is kept upright andk is in the “OFF” posi-fuel may leak out of thel tank. PEN onous and can cause

THE HAZARD allow some gasoline orgasoline vapor, or getn your eyes, see yourely. If gasoline spills onwith soap and water. Ifn your clothing, change


2-5

WARNING

POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you couldbe burned. HOW TO AVOID THE HAZARD Always turn off the engine when refuel-ing. Do not refuel immediately after the en-gine has been running and is still veryhot. Do not spill gasoline on the engine orexhaust pipe/muffler when refueling.Never refuel while smoking, or in the vi-cinity of sparks, open flames, or othersources of ignition such as the pilotlights of water heaters and clothes dry-ers.

When transportivehicle, be surethat the fuel coction. Otherwise, carburetor or fueWHAT CAN HAPGasoline is poisinjuries. HOW TO AVOID If you should swinhale a lot of some gasoline idoctor immediatyour skin, wash gasoline spills oyour clothes.

WARNING

ZARD ning the engine in a

PEN are poisonous and maynsciousness and death

me. THE HAZARD your ATV in an area withtion.


2-6

POTENTIAL HAStarting or runclosed area. WHAT CAN HAPExhaust fumes cause loss of cowithin a short tiHOW TO AVOIDAlways operate adequate ventila

EBU00032

CATION

mbly g

mbly g

14. Engine oil dipstick15. Oil filter cartridge16. Coolant reservoir17. V-belt cooling duct check hose18. Rear brake lever19. Left handlebar switches20. Starter (choke)21. Drive select lever22. Speedometer unit23. Main switch24. Fuel tank cap25. Auxiliary DC jack26. Right handlebar switch27. Throttle lever28. Front brake lever

ave purchased may differ slightly the figures of this manual.


3-1

9. Radiator cap10. Fuel cock11. Air filter case12. Fuses13. Tail/brake light

NOTE:The machine you hfrom those shown in

1-DESCRIPTION
AND MACHINE ID
1. Rear shocspring pre

2. Spark arre3. Storage co

and tool ki4. Spark plug5. Rear brak6. Front shoc

spring pre7. Brake ped8. V-belt cas

ENTIFI

k absorber asseload adjusting rinstermpartment

t

e fluid reservoirk absorber asseload adjusting rinale

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numbertion number is stamped on in the following illustration.be used for ordering a new

ber


3-2

EBU00600

Identification number recordsRecord the key identification number, vehicleidentification number and model label infor-mation in the spaces provided for assistancewhen ordering spare parts from a Yamahadealer or for reference in case the vehicle isstolen.1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUMBER:

3. MODEL LABEL INFORMATION:

EBU00035

Key identificationThe key identificathe key as shownThis number can key.

1. Key identification num

EBU00036 EBU00787

ffixed to the location in the the information on this la-vided. This information willer spare parts from your


3-3

Vehicle identification numberThe vehicle identification number is stampedinto the frame.

1. Vehicle identification number

NOTE:The vehicle identification number is used toidentify your machine.

Model labelThe model label is aillustration. Recordbel in the space probe needed to ordYamaha dealer.

1. Model label

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4-1

EBU00039

1-CONTROL FUNCTIONS


EBU09420

Main switchFunctions of the respective switch positionsare as follows: ON: The engine can be started only at this positionand the headlights and taillight come on whenthe light switch is on. OFF: All electrical circuits are switched off. The keycan be removed in this position.

1. Main switch

EBU08020 EBU10601

ck indicator light “DIFF.

and the differential gear display come on when thek switch is set to the “4WD-

set to “LOCK”, the differ-icator light will flash until is locked.

or light “L” comes on when the drive “L” position.

tor light “H” comes on when the drive “H” position.


4-2

Indicator and warning lights

1. Differential gear lock indicator light “DIFF. LOCK”2. Low-range indicator light “L”3. High-range indicator light “H”4. Neutral indicator light “N”5. Reverse indicator light “R”6. Park indicator light “P”7. Differential gear lock indicator “ ”8. Coolant temperature warning light “ ”

Differential gear loLOCK” This indicator lightlock indicator in thedifferential gear locLOCK” position.

NOTE:_

When the switch isential gear lock indthe differential gear_

EBU11220

Low-range indicatThis indicator light select lever is in the

EBU01064

High-range indicaThis indicator light select lever is in the

DIFF.LOCK

indicator “ ”/“ ” es on when the “2WD”/

t to the “4WD” position. Thek indicator “DIFF.LOCK” ine indicator also comes on

-“4WD” switch is set to thetion.

ronizing mechanism in these, the four-wheel drive in-me on until the ATV starts

DIFF.LOCK


4-3

EBU09720

Neutral indicator light “N” This indicator light comes on when the driveselect lever is in the “N” position.

EBU12500

Reverse indicator light “R”This indicator light comes on when the driveselect lever is in the “R” position.

EBU00609

Park indicator light “P”This indicator light comes on when the driveselect lever is in the “P” (park) position.

EBU11312

Four-wheel-driveThis indicator com“4WD” switch is sedifferential gear locthe four-wheel-drivwhen the “LOCK”“4WD-LOCK” posi

NOTE:_

Due to the synchdifferential gear cadicator may not comoving. _

EBU00860 EBU00052

cates the amount of fuel inn the needle reaches thenk at the first opportunity.

2. Red line

out of fuel, move the fuel“RES” position. Approxi-Imp gal, 1.19 US gal) ofg in the tank.


4-4

Coolant temperature warning light “ ”When the coolant temperature reaches aspecified level, this light comes on to warnthat the coolant temperature is too hot. If thelight comes on during operation, stop the en-gine as soon as it is safe to do so and allowthe engine to cool down for about 10 minutes.

CAUTION:_

� The engine may overheat if the ATV isoverloaded. If this happens, reducethe load to specification.

� After restarting, make sure that thelight is out. Continuous use while thelight is on may cause damage to theengine.

_

Fuel gaugeThe fuel gauge indithe fuel tank. Whered line, refill the ta

1. Fuel gauge

NOTE:_

If the machine runscock lever to the mately 4.5 L (0.99fuel will be remainin_

(which show the distanceey were last set to zero)

which shows the total timen turned to “ON”)


4-5

EBU11322

Speedometer unit

1. Speedometer 2. Odometer/Tripmeter A/Tripmeter B3. Clock/Hour meter 4. TRIP/ODO button5. Clock/Hour button “ ”/“ ” 6. “H” button 7. “M” button

The speedometer unit is equipped with thefollowing:� a speedometer (which shows the riding

speed)� an odometer (which shows the total dis-

tance traveled)

� two tripmeters traveled since th

� a clock� an hour meter (

the key has bee

“ ” button switches thehe clock mode “CLOCK”r mode “HOUR” in the fol-

CLOCK

to the clock mode./“ ” button until the clock

y pushing the “H” button.s by pushing the “M” but-

”/“ ” button, and then re- the clock.


4-6

Odometer and tripmeter modesPushing the “TRIP/ODO” button switches thedisplay between the odometer mode “ODO”and the tripmeter modes “A” and “B” in the fol-lowing order:ODO→TRIP A→TRIP B→ODOTo reset a tripmeter, select it by pushing the“TRIP/ODO” button, and then push the “TRIP/ODO” button for at least three seconds. Thetripmeters can be used to estimate the dis-tance that can be traveled with a full tank of fu-el. This information will enable you to planfuture fuel stops.

NOTE:_

Holding in the “TRIP/ODO” button and thenturning the key to “ON” switches the displaybetween “mph” and “km/h”. _

Clock modePushing the “ ”/display between tand the hour metelowing order:CLOCK→HOUR→

To set the clock1. Set the display2. Push the “ ”

starts flashing.3. Set the hours b4. Set the minute

ton.5. Push the “

lease it to start

eadlights with the engineore than thirty minutes. discharge to the pointmotor will not operateshould happen, removecharge it.

ch “ / ” engine stop switch is set tog the engine. The engine

ls ignition and can be used the engine, especially in anngine will not start or runtop switch is set to “ ”.


4-7

EBU00053

Handlebar switches

1. Light switch “ / /OFF”2. Start switch “ ”3. Engine stop switch “ / ”4. Override switch “OVERRIDE”

EBU12040

Light switch “ / /OFF”Set the switch to “ ” to turn on the low beamand the taillight.Set the switch to “ ” to turn on the highbeam and the taillight.Set the switch to “OFF” to turn off all the lights.

CAUTION:_

Do not use the hturned off for mThe battery maythat the starter properly. If this the battery and re_

EBU12050

Engine stop switMake sure that the“ ” before startinstop switch controat all times to stopemergency. The ewhen the engine s

EBU00607

RIDE”

OVERRIDE”ally limited when operatingonditions require more en-riding forward, push and override the 4WD-LOCKtion. (See page 4-11 for an about the differentiald its function.) Releasing

the speed limiting function. pushed, the segments ofigits will appear as shown


4-8

Start switch “ ”The starter motor cranks the engine when thisswitch is pushed.

CAUTION:See starting instructions prior to startingthe engine. (See page 6-1 for details.)

1. Override switch “OVER

EBU13781

Override switch “Top speed is normin 4WD-LOCK. If cgine power when hold this switch tospeed limiting funcdetailed explanatiogear lock switch anthe switch restores While this switch isthe speedometer din the figure.

WARNING

ZARD t while the ATV is in

PEN at the same speed whenis locked, so it takesrn the ATV. The amount the faster you go. Youl and have an accident ifke a sharp enough turnu are traveling. THE HAZARD a slow speed when the-LOCK, and allow extrace for maneuvers.


4-9

NOTE:_

If the digits of the speedometer appear asshown when the switch is NOT being pushed,this could indicate a malfunction in the electri-cal system. In this case, take the ATV to aYamaha dealer at the first opportunity. _

POTENTIAL HARiding too fas4WD-LOCK. WHAT CAN HAPAll wheels turn the differential more effort to tuof effort is moremay lose controyou cannot mafor the speed yoHOW TO AVOIDAlways ride at ATV is in 4WDtime and distan

(4WD): Power is suppliedont wheels. with the differential gearCK): Power is supplied tot wheels when the differen-ed (“DIFF.LOCK”). Unlikeall wheels turn at the same


4-10

1. On-Command four-wheel drive switch “2WD”/“4WD”2. Differential gear lock switch “LOCK”/“4WD”

EBU14091

On-Command four-wheel drive and differ-ential gear lock switchesThis ATV is equipped with an On-Commandfour-wheel drive switch “2WD”/“4WD” and adifferential gear lock switch “LOCK”/“4WD”.Select the appropriate drive according to ter-rain and the conditions.� Two-wheel drive (2WD): Power is supplied

to the rear wheels only.

� Four-wheel driveto the rear and fr

� Four-wheel drivelocked (4WD-LOthe rear and frontial gear is lockthe 4WD mode, speed.

heel drive switch “2WD”/“4WD”

our-wheel drive switch

WD to 4WD, stop the ATV,witch to “4WD”. When thee 4WD indicator “ ” willedometer unit display.

WD to 2WD, stop the ATV, set to position a, and thenWD”.


4-11

1. Lever2. On-Command four-w

On-Command f“2WD”/“4WD” To change from 2and then set the sATV is in 4WD, thcome on in the speTo change from 4be sure the lever isset the switch to “2

WARNING

POTENTIAL HAZARD Changing from 2WD to 4WD or from4WD to 4WD-LOCK (“DIFF.LOCK”), orvice-versa while the ATV is moving. WHAT CAN HAPPEN The ATV handles differently in 2WDthan in 4WD and in 4WD-LOCK in somecircumstances. Changing from 2WD to4WD or from 4WD to 4WD-LOCK, orvice-versa while moving may cause theATV to unexpectedly handle differently.This could distract the operator and in-crease the risk of losing control and anaccident. HOW TO AVOID THE HAZARD Always stop the ATV before changingfrom 2WD to 4WD or from 4WD to4WD-LOCK, or vice-versa.

WARNING

ARD while the ATV is in

PEN t the same speed whenis locked, so it takesn the ATV. The amount the faster you go. You and have an accident ife a sharp enough turnu are traveling. THE HAZARD slow speed when the

LOCK, and allow extrae for maneuvers.


4-12

1. Differential gear lock switch “LOCK”/“4WD” 2. Lever

Differential gear lock switch “LOCK”/“4WD” To lock the differential gear in 4WD, make surethe On-Command four-wheel-drive switch isset to “4WD”, stop the ATV, move the lever toposition b, and then set the switch to “LOCK”.When the differential gear is locked, the differ-ential gear lock indicator (“DIFF.LOCK”) lightwill come on along with the indicator “ ” inthe speedometer unit display. To release the differential gear lock, stop theATV and set the switch to “4WD”.

DIFF.LOCK

POTENTIAL HAZRiding too fast4WD-LOCK. WHAT CAN HAPAll wheels turn athe differential more effort to turof effort is moremay lose controlyou cannot makfor the speed yoHOW TO AVOID Always ride at aATV is in 4WD-time and distanc

running, movement of thecrease the engine speed.d of the machine by varyingn. Because the throttle is machine will decelerate,ll return to an idle any timeed from the throttle lever.


4-13

NOTE:_

� When the switch is set to “LOCK”, the dif-ferential gear lock indicator light will flashuntil the differential gear is locked.

� When the indicator light is flashing, turn-ing the handlebar back and forth will helpthe differential gear lock to engage.

� Riding before the differential gear lock isproperly engaged (e.g., when the indica-tor light is flashing) will cause the enginespeed to be limited until engagement iscomplete.

� When the ATV is in 4WD-LOCK, themaximum traveling speed is limited to35 km/h (22 mph). However, if conditionsrequire full engine power to be available,push and hold the override switch to dis-able the 4WD-LOCK speed limiter. (Seepage 4-8 for a detailed explanation of thisswitch.)

_

EBU00062

Throttle leverOnce the engine isthrottle lever will inRegulate the speethe throttle positiospring-loaded, theand the engine withe hand is remov

1. Throttle lever

EBU01159

eeps the throttle from fullyen the throttle lever isimum. Turning in the ad-the maximum engine pow-decreases the maximum

2. Adjusting screw0.47 in)


4-14

Before starting the engine, check the throttleto be sure it is operating smoothly. Make sureit returns to the idle position as soon as the le-ver is released.

Speed limiterThe speed limiter kopening, even whpushed to the maxjusting screw limits er available and speed of the ATV.

1. Locknuta. No more than 12 mm (

WARNING

POTENTIAL HAZARDMalfunction of throttle.WHAT CAN HAPPENThe throttle could be hard to operate,making it difficult to speed up or slowdown when you need to. This couldcause an accident.HOW TO AVOID THE HAZARDCheck the operation of the throttle leverbefore you start the engine. If it does notwork smoothly, check for the cause.Correct the problem before riding theATV. Consult a Yamaha dealer if youcan’t find or solve the problem yourself.

ver is located on the rightoward the handlebar to ap-.

rear brake lever located on the right side ofar brake lever is located on

Push down on the pedal orard the handlebar to apply


4-15

EBU00070

Front brake leverThe front brake lehandlebar. Pull it tply the front brake

1. Front brake lever

EBU00732

Brake pedal and The brake pedal isthe ATV and the rethe left handlebar.pull the lever towthe rear brake.

WARNING

POTENTIAL HAZARDImproper adjustment of the speed limit-er and throttle.WHAT CAN HAPPENThe throttle cable could be damaged.Improper throttle operation could result.You could lose control, have an acci-dent or be injured.HOW TO AVOID THE HAZARDDo not turn the adjusting screw outmore than 12 mm (0.47 in). Always makesure the throttle lever free play is adjust-ed to 3.0–5.0 mm (0.12–0.20 in). Seepage 8-38.

EBU00608

er is used to shift your ma-high, neutral, reverse ander to page 6-4 for the driveon.)


4-16

1. Brake pedal

1. Rear brake lever

Drive select leverThe drive select levchine into the low, park positions. (Refselect lever operati

1. Drive select lever

WARNING

ZARD ine without setting the

er to the park position

PEN start to move unexpect-ld cause an accident. THE HAZARD lect lever to the park po-rting the engine.


4-17

EBU00855

Recoil starterFirmly grasp the handle and pull slightly untilengagement can be felt. Then pull forcefully,being careful not to pull the rope all the wayout.

1. Recoil starter

POTENTIAL HAStarting the engdrive select lev“P”. WHAT CAN HAPThe ATV could edly, which couHOW TO AVOIDSet the drive sesition before sta

EBU00092 EBU00930

lies fuel from the fuel tank

hree positions.r in this position, fuel willays turn the lever to this

n the engine is not running.r in this position, fuel flowsetor. Normal riding is doner in this position.s reserve. If you run out ofing, turn the lever to thisN FILL THE FUEL TANK

ST OPPORTUNITY. Afterturn the fuel cock lever toition.


4-18

Fuel tank capRemove the fuel tank cap by turning it coun-terclockwise.

1. Fuel tank cap

Fuel cockThe fuel cock suppto the carburetor. The fuel cock has tOFF: With the leve

not flow. Alwposition whe

ON: With the leveto the carburwith the leve

RES: This indicatefuel while ridposition. THEAT THE FIRrefuelling, rethe “ON” pos

o “RES”


4-19

1. Arrow mark pointing to “OFF”

1. Arrow mark pointing to “ON”

1. Arrow mark pointing t

OFF Position

ON Position

RES Position

EBU00095 EBU05670

t, pull the seat lock lever the seat at the rear.

2. Seat lock lever


4-20

Starter (choke) “ ”Starting a cold engine requires a richer air-fuelmixture. A separate starter circuit supplies thismixture.Move in direction a to turn on the starter(choke).Move in direction b to turn off the starter(choke).Refer to “Starting a cold engine” for proper op-eration. (See page 6-1.)

1. Starter (choke) “ ”

SeatTo remove the seaupward and pull up

1. Seat

ment

partment is located undere 4-20 for seat removal andures.) documents in the storageure to wrap them in a plas-ey will not get wet. Whenbe careful not to let any wa-e compartment.

hose at the bottom of theent. If any water collects inthe hose, empty it, and then

imit: 2.0 kg (4 lb)


4-21

To install the seat, insert the projections onthe front of the seat into the seat holders andpush down on the seat at the rear.

NOTE:_

Make sure that the seat is securely fitted. _

1. Projection (× 2) 2. Seat holder (× 2)

EBU15230

Storage compart

The storage comthe seat. (See paginstallation procedWhen storing anycompartment, be stic bag so that thwashing the ATV, ter enter the storag

NOTE:_

There is a check storage compartmthis hose, remove install it. _

Maximum load l

EBU00582

it: 40 kg (88 lb)

it: 80 kg (176 lb)


4-22

1. Storage compartment

1. Storage compartment check hose

Front carrier

EBU00583

Rear carrier

Maximum load lim

Maximum load lim

ing ring

h can be obtained at amake this adjustment.

n: 2 oft) hard)


4-23

EBU15220

Front and rear shock absorber adjustment The spring preload can be adjusted to suit therider’s weight and riding conditions.Adjust the spring preload as follows. To increase the spring preload, turn the ad-justing ring in direction a. To decrease the spring preload, turn the ad-justing ring in direction b.

1. Spring preload adjust2. Position indicator

NOTE:_

A special wrencYamaha dealer to _

Standard positio1- Minimum (s5- Maximum (

WARNING

ARD absorber adjustment. PEN ent can cause poorss of stability, whichaccident. THE HAZARD e shock absorbers on

t side to the same set-


4-24

1. Special wrench

POTENTIAL HAZImproper shock WHAT CAN HAPUneven adjustmhandling and locould lead to an HOW TO AVOID Always adjust ththe left and righting.

xiliary DC jack is not being with the cap.

accessories requiringe above maximum capac- overload the circuit ande to blow. s are used without the

ng or with the headlightsthe battery will lose itsengine starting may be-lt. an automotive cigarette

ther accessories with ats hot because the jackged.

capacity for the auxiliary

W (10 A)


4-25

EBU10020

Auxiliary DC jackThe auxiliary DC jack is located at the frontright side of the ATV. The auxiliary DC jack can be used for suitablework lights, radios, etc. The auxiliary DC jack should only be usedwhen the engine is running. 1. Set the light switch to “OFF”.

1. Auxiliary DC jack cap

2. Start the engine. (See pages 6-1–6-3.)3. Open the auxiliary DC jack cap, and then

insert the accessory power plug into thejack.

4. When the auused, cover it

CAUTION:_

� Do not usemore than thity. This maycause the fus

� If accessorieengine runniturned on, charge and come difficu

� Do not use lighter or oplug that gecan be dama

_

Maximum rated DC jack:

DC 12 V, 120

ntial hazard that couldjury or death.


4-26

1. Auxiliary DC jack

EBU00112

WARNINGIndicates a poteresult in serious in

1

2

3

4

5

6

7

8

9

10

11

12

13

14

PAGE

akage. 5-2–5-3, 8-39–8-43

akage. 5-2–5-3, 8-40–8-45

5-4–5-5

5-6, 8-12–8-17

5-7, 8-22–8-27

5-6, 8-17–8-22

y. 5-7, 8-38

5-8–5-11, 8-49–8-50

5-8

5-8, 8-45, 8-54–8-59

8-27–8-28


5-1

1-PRE-OPERATION CHECKS

Before using this machine, check the following points:

ITEM ROUTINE

Front brake • Check operation, lever free play, fluid level and fluid le• Fill with DOT 4 brake fluid if necessary.

Rear brake • Check operation, lever free play, fluid level and fluid le• Fill with DOT 4 brake fluid if necessary.

Fuel • Check fuel level. • Fill with fuel if necessary.

Engine oil • Check oil level. • Fill with oil if necessary.

Coolant reservoir • Check coolant level in reservoir.• Fill with coolant if necessary.

Final gear oil and differential gear oil • Check for leakage.

Throttle • Check for proper throttle cable operation and free pla

Wheels and tires • Check tire pressure, wear and damage.

Fittings and fasteners • Check all fittings and fasteners.

Lights and switches • Check for proper operation.

Axle boots • Check for damage.

EBU11011

kesbrake pedal is no free play in the fronthere is free play, have adjust it.

t free play in the rear brakeplay is incorrect, adjust it.–8-45.) t brake pedal height. If thencorrect, have a Yamaha

ation of the brake leversy should move smoothly be a firm feeling when theed. If not, have a Yamahae brake system.

id level. Add fluid if neces--41–8-42.)

rake fluid: DOT 4


5-2

Front and rear braBrake levers and � Check that there

brake lever. If tYamaha dealer a

� Check for correclever. If the free (See pages 8-44

� Check for correcpedal height is idealer adjust it.

� Check the operand pedal. Theand there shouldbrakes are applidealer inspect th

Brake fluid levelCheck the brake flusary. (See pages 8

WARNING

POTENTIAL HAZARDFailure to inspect the ATV before oper-ating. Failure to properly maintain the ATV.WHAT CAN HAPPENIncreases the possibility of an accidentor equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV each time youuse it to make sure the ATV is in safe op-erating condition.Always follow the inspection and main-tenance procedures and schedules de-scribed in the Owner’s Manual.

Recommended b

WARNING

ZARD improperly operating

PEN braking ability, which accident. THE HAZARD e brakes at the start of

not ride the ATV if youm with the brakes. If a be corrected by the ad-dures provided in thisamaha dealer check for


5-3

Brake fluid leakageCheck to see if any brake fluid is leaking out ofthe pipe joints or brake fluid reservoirs. Applythe brakes firmly for one minute. If the levermoves slowly inward, there may be a leak inthe brake system. If there is any leakage, thebrake system should be inspected by aYamaha dealer.

Brake operationTest the brakes at slow speed after startingout to make sure they are working properly. Ifthe brakes do not provide proper braking per-formance, inspect the brake pads for wear.(See pages 8-39–8-40.)

POTENTIAL HARiding with brakes. WHAT CAN HAPYou could losecould lead to anHOW TO AVOIDAlways check thevery ride. Do find any probleproblem cannotjustment procemanual, have a Ythe cause.

EBU01085

ine has been designed toed gasoline with a pump+M]/2) of 86 or higher, orumber of 91 or higher. Ifg occurs, use a differentr premium unleaded fuel.ive you longer spark plugintenance cost.


5-4

FuelMake sure there is sufficient gasoline in thetank.

CAUTION:_

Use only unleaded gasoline. The use ofleaded gasoline will cause severe damageto internal engine parts, such as the valvesand piston rings, as well as to the exhaustsystem. _

Your Yamaha enguse regular unleadoctane number ([Rresearch octane nknocking or pinginbrand of gasoline oUnleaded fuel will glife and reduced ma

Recommended fuel: UNLEADED GASOLINE ONLY

Fuel tank capacity: Total:

15.0 L (3.30 Imp gal, 3.96 US gal) Reserve:

4.5 L (0.99 Imp gal, 1.19 US gal)

WARNING

ZARD hen refueling. PEN

which can cause a firey. hen it heats up. If the

filled, fuel could spill out the engine or the sun. THE HAZARD he fuel tank. Be carefulespecially on the engine Wipe up any spilled fuel sure the fuel tank cap is. ght after the engine hasd is still very hot.


5-5

Gasohol There are two types of gasohol; gasohol con-taining ethanol and that containing methanol.Gasohol containing ethanol can be used ifethanol content does not exceed 10%. Gaso-hol containing methanol is not recommendedby Yamaha because it may cause fuel systemdamage or vehicle performance problems.

1. Fuel level 2. Fuel tank filler tube

POTENTIAL HAImproper care wWHAT CAN HAPFuel can spill, and severe injurFuel expands wfuel tank is overdue to heat fromHOW TO AVOIDDo not overfill tnot to spill fuel, or exhaust pipe.immediately. Beclosed securelyDo not refuel ribeen running an

EBU10842 EBU00493

gear oil is at the specifiedessary. (See pages 8-17–

0W90 hypoid gear oil mayitions.

nd additive rating, GL-5 orear oils may also be used.

ilerential gear oil is at thed oil as necessary. (Seer details.)

il:L-4 Hypoid gear oil

il:L-4 Hypoid gear oil


5-6

Engine oilMake sure the engine oil is at the specifiedlevel. Add oil as necessary. (See pages 8-12–8-17.)

CAUTION:_

� In order to prevent clutch slippage(since the engine oil also lubricatesthe clutch), do not mix any chemicaladditives. Do not use oils with a dieselspecification of “CD” or oils of a high-er quality than specified. In addition,do not use oils labeled “ENERGYCONSERVING II” or higher.

� Make sure that no foreign material en-ters the crankcase.

_

Final gear oilMake sure the finallevel. Add oil as nec8-20 for details.)

If desired, an SAE 8be used for all cond

NOTE:GL-4 is a quality aGL-6 rated hypoid g

EBU00678

Differential gear oMake sure the diffspecified level. Adpages 8-20–8-22 fo

Recommended engine oil type and quantity:

See page 10-2.

Recommended oSAE 80 API G

Recommended oSAE 80 API G

the throttle lever operatesopen smoothly and springsition when released. Haver repair as necessary for

WARNING

ZARD diator cap when the en-r are still hot. PEN urned by hot fluid andt under pressure. THE HAZARD gine to cool before re-iator cap. Always use athe cap. Allow any re-ure to escape beforeoving the cap.


5-7

EBU12530

Coolant Check the coolant level in the coolant reser-voir when the engine is cold. (The coolant lev-el will vary with engine temperature.) Thecoolant level is satisfactory if it is between theminimum and maximum level marks on thecoolant reservoir. If the coolant level is at orbelow the minimum level mark, add distilledwater to bring the level up to maximum levelmark. Change the coolant every two years.(See pages 8-22–8-27 for details.)

CAUTION:_

Hard water or salt water is harmful to theengine. You may use soft water if you can-not get distilled water. _ EBU01083

Throttle leverCheck to see thatcorrectly. It must back to the idle poa Yamaha dealeproper operation.

Coolant reservoir capacity (up to the maximum level mark):

0.25 L (0.22 Imp qt, 0.26 US qt)

POTENTIAL HARemoving the ragine and radiatoWHAT CAN HAPYou could be bsteam blown ouHOW TO AVOIDWait for the enmoving the radthick rag over maining presscompletely rem

EBU11620 EBU00157

WARNING

ARDTV with improper tires,r or uneven tire pres-

PENtires on this ATV, or op-V with improper or un-re, may cause loss ofing your risk of acci-

THE HAZARDed below have been ap-amaha Motor Co., Ltd.el. Other tire combina-

t recommended.

Size Type

AT25 × 8-12 M911Y

AT25 × 10-12 M912Y


5-8

Fittings and fasteners Always check the tightness of chassis fittingsand fasteners before a ride. Take the machineto a Yamaha dealer or refer to the ServiceManual for correct tightening torque.

EBU10030

Lights Check the headlights and tail/brake light tomake sure they are in working condition. Re-pair as necessary for proper operation.

EBU11700

Switches Check the operation of all switches. Have aYamaha dealer repair as necessary for properoperation.

Tires

POTENTIAL HAZOperating this Aor with impropesure.WHAT CAN HAPUse of improper eration of this ATeven tire pressucontrol, increasdent.HOW TO AVOID 1. The tires list

proved by Yfor this modtions are no

ACE-01E

Manufacturer

Front MAXXIS

Rear MAXXIS

ore than the followingwhen seating the tire

a (2.5 kgf/cm2, 36 psi)a (2.5 kgf/cm2, 36 psi)ssures may cause thet. Inflate the tires verycarefully. Fast inflation the tire to burst.


5-9

2. The tires should be set to the rec-ommended pressure:

� Recommended tire pressureFront 25 kPa (0.25 kgf/cm2, 3.6 psi)Rear 25 kPa (0.25 kgf/cm2, 3.6 psi)

� Check and adjust tire pressures whenthe tires are cold.

� Tire pressures must be equal on bothsides.

3. Tire pressure below the minimumspecified could cause the tire todislodge from the rim under severeriding conditions. The following are minimums:

Front 22 kPa (0.22 kgf/cm2, 3.2 psi)Rear 22 kPa (0.22 kgf/cm2, 3.2 psi)

4. Use no mpressures beads.

Front 250 kPRear 250 kP

Higher pretire to bursslowly and could cause

EBU00159

e


5-10

How to measure tire pressureUse the low-pressure tire gauge.

NOTE:The low-pressure tire gauge is included asstandard equipment. Make two measure-ments of the tire pressure and use the secondreading. Dust or dirt in the gauge could causethe first reading to be incorrect.

Set pressure with tires cold.Set tire pressures to the following specifica-tions:ACE-02EACE-02E

1. Low-pressure tire gaug

Recommended pressure

Minimum Maximum

Front25 kPa

(0.25 kgf/cm2, 3.6 psi)

22 kPa (0.22 kgf/cm2,

3.2 psi)

28 kPa (0.28 kgf/cm2,

4.0 psi)

Rear25 kPa

(0.25 kgf/cm2, 3.6 psi)

22 kPa (0.22 kgf/cm2,

3.2 psi)

28 kPa (0.28 kgf/cm2,

4.0 psi)


5-11

EBU00160

Tire wear limitWhen the tire groove decreases to 3 mm(0.12 in) due to wear, replace the tire.

a. Tire wear limit

EBU00161 EBU15110

gine

brake lever or brake pedal.ock to “ON”.switch to “ON” and the en-h to “ ”.

select lever into the neutraln.

WARNING

ARD cables in cold weather.PENable to control the ATV, to an accident or colli-

THE HAZARDcold weather, alwayscontrol cables work

you begin riding.


6-1

1-OPERATION


Starting a cold en

1. Apply the rear 2. Turn the fuel c3. Turn the main

gine stop switc4. Shift the drive

or park positio

WARNING

POTENTIAL HAZARDOperating ATV without being familiarwith all controls.WHAT CAN HAPPENLoss of control, which could cause anaccident or injury.HOW TO AVOID THE HAZARDRead the Owner’s Manual carefully. Ifthere is a control or function you do notunderstand, ask your Yamaha dealer.

POTENTIAL HAZFreezing controlWHAT CAN HAPYou could be unwhich could leadsion.HOW TO AVOID When riding in make sure all smoothly before

1

2

3

4

5

6

7

8

9

10

11

12

13

14

engine start-ent temperature above (80 °F) and warm engine

position.

1. Fully open3. Closed

lose the throttle lever andine by pushing the start


6-2

NOTE:_

� When the drive select lever is in the neu-tral or park position, if either indicator lightdoes not come on, ask a Yamaha dealerto inspect the respective electric circuit.

� The engine can be started in any gear ifthe rear brake lever or brake pedal is ap-plied. However, it is recommended toshift into neutral or park before startingthe engine.

_

5. Use the starter (choke) in reference tothe figure:

Position 1 : Cold engine start-ambient temperature below 5 °C(40 °F).

Position 2 : Cold engine start-ambient temperature at 0 °C(30 °F)–30 °C (90 °F) andwarming up position.

Position 3 : Coldambi25 °Cstart

a. Starter (choke) 2. Half open

6. Completely cstart the engswitch.

reak-in” section prior toine for the first time.

ngineine, refer to the “Starting aion. The starter (choke)d. The throttle should be

ngine life, always warm uptarting off. Never acceler- engine! To see whether orrm, check if it responds to

ly with the starter (choke)


6-3

NOTE:_

� If the engine fails to start, release thestart switch, then push the start switchagain. Pause a few seconds before thenext attempt. Each cranking should be asshort as possible to preserve battery en-ergy. Do not crank the engine more than10 seconds on each attempt.

� If the battery is discharged, pull the recoilstarter to start the engine.

_

7. If the engine is started with the starter(choke) in position 1, the starter (choke)should be returned to position 2 to warmup the engine. If the engine is started withthe starter (choke) in position 2, keepthe starter (choke) in this position towarm up the engine.

8. Continue warming up the engine until itidles smoothly and return the starter(choke) to position 3 before riding.

CAUTION:_

See the “Engine boperating the eng_

EBU00180

Starting a warm eTo start a warm engcold engine” sectshould not be useopened slightly.

EBU00182

Warming upTo get maximum ethe engine before sate hard with a coldnot the engine is wathe throttle normalturned off.

ttle lever gradually.


6-4

EBU08461

Drive select lever operation and reverse driving

CAUTION:_

Before shifting, you must stop the ATVand return the throttle lever to the closedposition, otherwise the transmission maybe damaged. _

Shifting: Neutral to High and High to Low1. Bring the ATV to a complete stop and re-

turn the throttle lever to the closed posi-tion.

2. Apply the brakes, then shift by movingthe drive select lever along the shiftguide.

NOTE:_

Make sure that the drive select lever is com-pletely shifted into position. _


3. Open the thro

rse, the reverse indicator on. If the light does not Yamaha dealer to inspectircuit.nchronizing mechanism in light may not come on un-ts moving.

for people or obstacles,se the brake pedal.


6-5

Shifting: Neutral to Reverse and Reverseto Park

NOTE:_

The drive select lever cannot be shifted into orfrom reverse or park without applying the rearbrake. _

1. Bring the ATV to a complete stop and re-turn the throttle lever to the closed posi-tion.

2. Apply the brake pedal.3. Shift from neutral to reverse or from re-

verse to park and vice versa by movingthe drive select lever along the shiftguide.


NOTE:_

� When in revelight should become on, ask athe electrical c

� Due to the sythe engine, thetil the ATV star

_

4. Check behindand then relea


6-6

5. Open the throttle lever gradually and con-tinue to watch to the rear while backing.

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person be-hind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make surethere are no obstacles or people behindyou. When it is safe to proceed, go slow-ly.

EBU02101

acceleration sequence with a substantial rest pe- by cruising at lower r/minrid itself of the temporary

is noticed during this peri-ha dealer.

peration above half throt-off period of five to ten min-ur of operation. Vary theine from time to time. Doe set throttle position.


6-7

Engine break-inThere is never a more important period in thelife of your machine than the period betweenzero and 20 hours. For this reason, we ask that you carefully readthe following material. Because the engine isbrand new, you must not put an excessiveload on it for the first several hours of running.During the first 20 hours, the various parts inthe engine wear and polish themselves to thecorrect operating clearances. During this period, prolonged full throttle oper-ation or any condition which might result in ex-cessive engine heating must be avoided.However, momentary (2–3 seconds maxi-mum) full throttle operation under load doesnot harm the engine.

Each full throttleshould be followedriod for the engineso the engine can build up of heat. If any abnormality od, consult a Yama

0–10 hours: Avoid continuous otle. Allow a cooling utes after every hospeed of the machnot operate it at on

p the engine and shift theinto the park position, theno the “OFF” position.


6-8

10–20 hours: Avoid prolonged operation above 3/4 throttle.Rev the machine freely but do not use fullthrottle at any time.

After break-in: Avoid prolonged full throttle operation. Varyspeeds occasionally.

EBU00612

ParkingWhen parking, stodrive select lever turn the fuel cock t

EBU06151

hine to a stop by applying

e.e pedal applied, shift theer to the park position “P”.


6-9

Parking on a slope 1. Bring the macthe brakes.

2. Stop the engin3. With the brak

drive select lev

WARNING

POTENTIAL HAZARDParking on a hill or other incline.WHAT CAN HAPPENThe ATV could roll out of control, in-creasing the chance of an accident.HOW TO AVOID THE HAZARDAvoid parking on hills or other inclines.If you must park on an incline, place themachine transversely across the in-cline, apply the parking brake, and blockthe front and rear wheels with rocks orother objects.Do not park the ATV at all on hills thatare so steep you could not walk up themeasily.

uld be rigidly and securelycessory which can shift po-ff while you are riding couldy to control the ATV.n accessory where it couldur ability to control the ATV.e (but are not limited to) a

object attached to the han-ould make steering difficult,at limits your ability to moveeat, or one that limits your

n when riding an ATV withe ATV may handle differ-s without accessories.


6-10

EBU00221

Accessories and loading

EBU00222

AccessoriesAccessories can affect the handling and con-trol of your ATV. Keep the following in mindwhen considering an accessory or operatingan ATV which has accessories.� Choose only accessories designed for your

ATV. Your Yamaha dealer has a variety ofgenuine Yamaha accessories. Other ac-cessories may also be available on themarket. However, it is not possible forYamaha to test all non-Yamaha accesso-ries, nor have any control over the quality orsuitability of them. Choose a genuineYamaha accessory, or one that is equiva-lent in design and quality.

� Accessories shomounted. An acsition or come oaffect your abilit

� Do not mount ainterfere with yoExamples includheavy or bulky dlebars which can accessory tharound on the sview.

� Use extra cautioaccessories. Thently than it doe

EBU15260

the maximum tongue measure tongue weight scale. Put the tongue ofer on the scale with theeight. Adjust the load in thery, to reduce the weight on

g cargo and towing a trail-ngue weight in the maxi-

d limit. he carrier as close to theicle as possible. Put cargoe front carrier and at ther carrier. Center the load. securely to the carriers. in the trailer cannot moveg load can cause an acci-

ad does not interfere withbility to see where you are


6-11

Loading Cargo or a trailer can change the stability andhandling of an ATV. You must use commonsense and good judgment when carrying car-go or towing a trailer. Keep the followingpoints in mind: � Never exceed the weight limits shown. An

overloaded ATV can be unstable.

� Do not exceedweight. You canwith a bathroomthe loaded trailtongue at hitch htrailer, if necessahitch. If you are carryiner, include the tomum vehicle loa

� Load cargo on tcenter of the vehat the rear of thfront of the reafrom side to side

� Tie down cargoMake sure cargoaround. A shiftindent.

� Make sure the locontrols or your agoing.

MAXIMUM LOADING LIMIT � Vehicle loading limit (total weight of

cargo, rider and accessories, and tongue weight): 210 kg (463 lb)

� Front carrier: 40 kg (88 lb) � Rear carrier: 80 kg (176 lb) � Storage compartment: 2.0 kg (4 lb) � Trailer hitch:

Pulling load (total weight of trailer and cargo): 500 kgf (1,102 lbf) Tongue weight (vertical weight on trailer hitch point): 15 kgf (33 lbf)

WARNING

ZARD ATV or carrying or tow-perly. PEN

hanges in vehicle han-ld lead to an accident. THE HAZARD he stated load capacity

be properly distributedttached. Reduce speedargo or pulling a trailer.stance for braking.


6-12

� Ride more slowly than you would without aload. The more weight you carry, the slow-er you should go. Although conditions vary,it is good practice not to exceed low rangewhenever you are carrying heavier loads orwhen towing a trailer.

� Allow more braking distance. A heavier ve-hicle takes longer to stop.

� Avoid making sharp turns unless at veryslow speeds.

� Avoid hills and rough terrain. Choose ter-rain carefully. Added weight affects the sta-bility and handling of the ATV.

POTENTIAL HAOverloading thising cargo improWHAT CAN HAPCould cause cdling which couHOW TO AVOIDNever exceed tfor this ATV. Cargo should and securely awhen carrying cAllow greater di

6-13

tential hazard that coulds injury or death.


EBU15280

WARNING_

Indicates a poresult in seriou

7


1-Riding

Your

ATV

7-1

WAR_

Indicates result in s

GETTINGThis ATV section, RATV ridingThe skillssection, hoof riding. skills acquof time. Taniques wemaneuver

l completely and understandthe controls. Pay particular at-afety information on pages also read all caution andn your ATV.


7-3

Riding your new ATV can be a very enjoyableactivity, providing you with hours of pleasure.But it is essential to familiarize yourself withthe operation of the ATV to achieve the skillnecessary to enjoy riding safely. Before youbegin to ride, be sure you have read this

NINGa potential hazard that could

erious injury or death.

TO KNOW YOUR ATV is for recreation and utility use. Thisiding your ATV, provides general instructions for recreational riding.

and techniques described in thiswever, are appropriate for all typesRiding your ATV requires specialired through practice over a periodke the time to learn the basic tech-ll before attempting more difficult

s.

Owner’s Manuathe operation of tention to the s2-1–2-6. Pleasewarning labels o

requires skills acquiredver a period of time. arn the basic techniques

ting more difficult maneu-

THE HAZARD experienced operators the certified training

y Yamaha. They shouldactice the skills learnednd the operating tech- in this Owner’s Manu-

nformation about the contact an authorizedll 1-800-887-2887.


7-4

RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced. Beginners should get training from a certifiedinstructor. Become familiar with this ATV at slow speedsfirst, even if you are an experienced operator.Do not attempt to operate at maximum perfor-mance until you are totally familiar with theATV’s handling and performance characteris-tics.

Riding your ATV through practice oTake the time to lewell before attempvers.

WARNING

POTENTIAL HAZARD Operating this ATV without proper in-struction. WHAT CAN HAPPEN The risk of an accident is greatly in-creased if the operator does not knowhow to operate the ATV properly in dif-ferent situations and on different typesof terrain.

HOW TO AVOID Beginning and inshould completecourse offered bthen regularly prin the course aniques describedal. For more itraining course,ATV dealer or ca


7-5

Not recommended for children under16 years of age.

WARNING

POTENTIAL HAZARD Failure to follow the age recommenda-tions for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec-ommended for their age can lead to se-vere injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operatean ATV with engine size greater than90cc.


7-6

This ATV is designed to carry operator andcargo only – passengers prohibited.

WARNING

POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balanceand control this ATV. Could cause anaccident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seatis to allow the operator to shift positionas needed during operation. It is not forcarrying passengers.

out protective clothinghances of severe injuryn accident. THE HAZARD n approved motorcycleproperly. wear: n

face shield)

shirt or jacket


7-7

Apparel

WARNING

POTENTIAL HAZARD Operating this ATV without wearing anapproved motorcycle helmet, eye pro-tection and protective clothing. WHAT CAN HAPPEN Operating withoutan approved motor-cycle helmet in-creases yourchances of a severehead injury or deathin the event of an ac-cident. Operating without eye protection can re-sult in an accident and increases yourchances of a severe injury in the eventof an accident.

Operating withincreases your cin the event of aHOW TO AVOIDAlways wear ahelmet that fits You should also

eye protectio(goggles or gloves boots long-sleevedlong pants

WARNING

ARD TV after consuming al-

PEN affect your judgment. to react more slowly. r balance and percep-

n accident. THE HAZARD alcohol or drugs beforehis ATV.


7-8

Do not operate after consuming alcohol ordrugs. Operator’s performance capability is reducedby the influence of alcohol or drugs.

POTENTIAL HAZOperating this Acohol or drugs. WHAT CAN HAPCould seriously Could cause youCould affect yoution. Could result in aHOW TO AVOID Never consume or while driving t

WARNING

ZARD TV with improper tires,

er or uneven tire pres-

PEN tires on this ATV, or op-TV with improper or un-ure, may cause loss ofing your risk of an acci-

THE HAZARD size and type tires spec-er’s Manual for this vehi-–5-9. proper tire pressure ase Owner’s Manual on


7-9

Pre-operation checks Always perform the pre-operation checks list-ed on page 5-1 before riding for safety andproper care of the ATV.

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before oper-ating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accidentor equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time youuse it to make sure the ATV is in safe op-erating condition. Always follow the inspection and main-tenance procedures and schedules de-scribed in the Owner’s Manual.

POTENTIAL HAOperating this Aor with impropsure. WHAT CAN HAPUse of impropereration of this Aeven tire presscontrol, increasdent. HOW TO AVOIDAlways use the ified in the Owncle on pages 5-8Always maintaindescribed in thpage 5-10.

erienced with this model,ped with a speed limiter inousing. The speed limiterfrom fully opening, evenver is pushed to the maxi- adjusting screw limits the

power available and de-um speed of the ATV.

ng screw in decreases topit out increases top speed.-15 for details.)

2. Adjusting screw


7-10

WARNING_

Indicates a potential hazard that couldresult in serious injury or death.

Do not operate at speeds too fast for yourskills or the conditions.

Speed limiter For riders less expthis model is equipthe throttle lever hkeeps the throttle when the throttle lemum. Turning in themaximum engine creases the maximTurning the adjustispeed and turning (See pages 4-14–4

1. Locknut

WARNING

POTENTIAL HAZARD Operating this ATV at speeds too fastfor your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing con-trol of the ATV, which can result in anaccident. HOW TO AVOID THE HAZARD Always go at a speed that is proper forthe terrain, visibility and operating con-ditions, and your experience.

WARNING

ZARD ATV or carrying or tow-perly. PEN

hanges in vehicle han-ld lead to an accident. THE HAZARD he stated load capacity

be properly distributedached. when carrying cargo or. Allow greater distance

he instructions in yourl for carrying cargo or


7-11

Loading and accessories Use extra caution when riding the ATV withadditional loads, such as accessories or car-go. The ATV’s handling may be adversely af-fected. Reduce your speed when addingadditional loads.

MAXIMUM LOADING LIMIT � Vehicle loading limit: 210 kg (463 lb)

* Total weight of cargo, rider and accessories, and trailer hitch vertical load.

� Front carrier: 40 kg (88 lb) � Rear carrier: 80 kg (176 lb) � Storage compartment: 2.0 kg (4 lb) � Trailer hitch:

Pulling load: 500 kgf (1,102 lbf) Total weight of trailer and cargo. Tongue weight: 15 kgf (33 lbf) Vertical weight on trailer hitch point.

POTENTIAL HAOverloading thising cargo improWHAT CAN HAPCould cause cdling which couHOW TO AVOIDNever exceed tfor this ATV. Cargo should and securely attReduce speed pulling a trailerfor braking.Always follow tOwner’s Manuapulling a trailer.

WARNING

ARD s from handlebars orrds during operation.

PEN ne hand or foot can re- to control the ATV or to lose your balance

e ATV. If you remove aboard, your foot or legcontact with the rearuld injure you or cause

THE HAZARD h hands on the handle-et on the footboards of operation.


7-12

During operation Always keep your feet on the footboards dur-ing operation. Otherwise your feet may con-tact the rear wheels.

POTENTIAL HAZRemoving handfeet from footboaWHAT CAN HAPRemoving even oduce your abilitycould cause youand fall off of thfoot from a footmay come into wheels, which coan accident. HOW TO AVOID Always keep botbars and both feyour ATV during


7-13

Avoid wheelies and jumping. You may losecontrol of the ATV or overturn.

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps, and otherstunts. WHAT CAN HAPPEN Increases the chance of an accident, in-cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheeliesor jumps. Don’t try to show off.


7-14

Modifications

WARNING

POTENTIAL HAZARD Operating this ATV with improper modi-fications. WHAT CAN HAPPEN Improper installation of accessories ormodification of this vehicle may causechanges in handling which in some situ-ations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improp-er installation or use of accessories. Allparts and accessories added to this ve-hicle should be genuine Yamaha orequivalent components designed foruse on this ATV and should be installedand used according to instructions. Ifyou have questions, consult an autho-rized ATV dealer.

e hot exhaust system. ATV in a place where

likely to touch it.


7-15

Exhaust system The exhaust system on the ATV is very hotduring and following operation. To preventburns, avoid touching the exhaust system.Park the ATV in a place where pedestrians orchildren are not likely to touch it.

WARNING

POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustiblematerial accumulated around the en-gine area could catch fire. Someone touching the exhaust systemduring or after operation could beburned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV indry grass or other dry ground cover. Keep the engine area free of dry grass,brush, or other combustible material.

Do not touch thDo not park theothers might be


7-16

BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only.Riding on paved surfaces can cause loss ofcontrol.

WARNING

POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affecthandling and control of the ATV, andmay cause the vehicle to go out of con-trol. HOW TO AVOID THE HAZARD Always avoid paved surfaces, includingsidewalks, driveways, parking lots andstreets.


7-17

Do not ride on any public road, street, or high-way. Riding on public roads can result in collisionswith other vehicles.

WARNING

POTENTIAL HAZARD Operating this ATV on public streets,roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any publicstreet, road or highway, even a dirt orgravel one. In many states it is illegal tooperate ATVs on public streets, roadsand highways.


7-18

Know the terrain where you ride. Ride cau-tiously in unfamiliar areas. Stay alert forholes, rocks, or roots in the terrain, and oth-er hidden hazards which may cause the ATVto upset.

WARNING

POTENTIAL HAZARD Failure to use extra care when operatingthis ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks,bumps, or holes, without enough time toreact. Could result in the ATV overturn-ing or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when op-erating on unfamiliar terrain. Always bealert to changing terrain conditionswhen operating the ATV.


7-19

WARNING

POTENTIAL HAZARD Failure to use extra care when operatingon excessively rough, slippery or looseterrain. WHAT CAN HAPPEN Could cause loss of traction or vehiclecontrol, which could result in an acci-dent, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough,slippery or loose terrain until you havelearned and practiced the skills neces-sary to control the ATV on such terrain. Always be especially cautious on thesekinds of terrain.

s posted “no trespassing”.te property without getting

PEN a collision. You could

THE HAZARD caution flag on the ATVre visible. Watch care-hicles.


7-20

When riding in an area where you might noteasily be seen, such as desert terrain, mounta caution flag on the ATV. DO NOT use theflag pole bracket as a trailer hitch.

Do not ride in areaDo not ride on privapermission.

WARNING

POTENTIAL HAZARD Operating in areas where you might notbe seen by other off-road vehicles.

WHAT CAN HAPYou could be inbe injured. HOW TO AVOID Always mount a to make you mofully for other ve

ling, shift the drive select le-ition “L” or the high positionottle slowly and smoothly.tch will engage and you will. If the throttle is applied toot wheels may lift off the a loss of directional con-speeds until you are thor- the operation of your ATV.

n or stopping, release the the brakes smoothly andse of the brakes can causection, reducing control andsibility of an accident.

drive position low “L” toersa without coming to aamage to the engine or

ccur.


7-21

Select a large, flat area off-road to become fa-miliar with your ATV. Make sure that this areais free of obstacles and other riders. Youshould practice control of the throttle, brakes,shifting procedures, and turning techniques inthis area before trying more difficult terrain. Al-ways avoid riding on paved surfaces: the ATVis designed for off-road use only, and han-dling maneuvers are more difficult to performon pavement.

Shift to the parking position “P” and follow theinstruction on page 6-1 to start the engine.Once it has warmed up you are ready to beginriding your ATV. Remember that the engineand exhaust pipe will be hot when riding andafterwards; do not allow skin or clothing tocome in contact with these components.

With the engine idver to the low pos“H”. Apply the thrThe centrifugal clustart to accelerateabruptly, the fronground resulting introl. Avoid higher oughly familiar with

When slowing dowthrottle and applyevenly. Improper uthe tires to lose traincreasing the pos

CAUTION:_

Do not shift fromhigh “H” or vice vcomplete stop. Ddrive train may o_

curve, slow down and be-lebars in the desired direc-, put your weight on thetside of the turn (opposite

tion) and lean your upperse the throttle to maintain

ugh the turn. This maneu-el on the inside of the turng the ATV to make the turn

THE HAZARD roper procedures forribed in this Owner’s

at low speeds before at-at faster speeds. Do noto fast for your skills or

speed and allow extrae for maneuvers whenIFF. LOCK”).


7-22

TURNING YOUR ATV To achieve maximum traction while riding off-road in 2WD or 4WD, the two rear wheels aremounted solidly on one axle and turn togetherat the same speed. Furthermore, when ridingin 4WD-LOCK (“DIFF. LOCK”), the frontwheels also turn together at the same speed.Therefore, unless the wheel on the inside ofthe turn is allowed to slip or lose some trac-tion, the ATV will resist turning. A special turn-ing technique must be used to allow the ATVto make turns quickly and easily. It is essentialthat this skill be learned first at low speed. As you approach a

gin to turn the handtion. As you do sofootboard to the ouyour desired direcbody into the turn. Uan even speed throver will let the wheslip slightly, allowinproperly.

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing acollision or overturn.

HOW TO AVOID Always follow pturning as descManual. Practice turning tempting to turn turn at speeds tothe conditions. Operate at a slowtime and distancin 4WD-LOCK (“D

earned this technique youperform it at higher speeds.

rocedures such as abruptxcessive braking, incorrect

or too much speed for theurn may cause the ATV toins to tip over to the outside turn, lean more to the in-

e necessary to gradually letand steer to the outside ofpping over. higher speeds until you are with the operation of your


7-23

This procedure should be practiced at slowspeed many times in a large off-road areawith no obstacles. If an incorrect technique isused, your ATV may continue to go straight. Ifthe ATV doesn’t turn, come to a stop and thenpractice the procedure again. If the riding sur-face is slippery or loose, it may help to posi-tion more of your weight over the front wheelsby moving forward on the seat.

Once you have lshould be able to or in tighter curves

Improper riding pthrottle changes, ebody movements,sharpness of the ttip. If the ATV begwhile negotiating aside. It may also boff on the throttle the turn to avoid tiRemember: Avoidthoroughly familiarATV.

n climbing a hill to makeht is transferred forward onbe accomplished by lean- steeper inclines, standingand leaning forward over

THE HAZARD e ATV on hills too steepr your abilities. Practicebefore attempting large


7-24

CLIMBING UPHILL Use proper riding techniques to avoid vehicleoverturns on hills. Be sure that you can ma-neuver your ATV well on flat ground before at-tempting any incline and then practice ridingfirst on gentle slopes. Try more difficult climbsonly after you have developed your skill. In allcases avoid inclines with slippery or loose sur-faces, or obstacles that might cause you tolose control.

It is important whesure that your weigthe ATV. This can ing forward and, onon the footboards the handlebars.

WARNING

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily onextremely steep hills than on level sur-faces or small hills.

HOW TO AVOID Never operate thfor the ATV or foon smaller hills hills.

sharp drop, or anothern could be on the other


7-25

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause theATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures forclimbing hills as described in this Own-er’s Manual. Always check the terrain carefully be-fore you start up any hill. Never climb hills with excessively slip-pery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at highspeed.

An obstacle, a vehicle or persoside of the hill.

WARNING

ARD ing hills or turning on

PEN of control or cause the

THE HAZARD turn the ATV around

you have mastered thee as described in the

l on level ground. Been turning on any hill.he side of a steep hill if


7-26

If you are climbing a hill and you find that youhave not properly judged your ability to makeit to the top, you should turn the ATV aroundwhile you still have forward motion (providedyou have the room to do so) and go down thehill.

POTENTIAL HAZImproperly crosshills. WHAT CAN HAPCould cause lossATV to overturn.HOW TO AVOID Never attempt toon any hill until turning techniquOwner’s Manuavery careful whAvoid crossing tpossible.


7-27

When crossing the side of a hill: Always follow proper procedures as de-scribed in the Owner’s Manual. Avoid hills with excessively slippery orloose surfaces. Shift your weight to the uphill side of theATV.

brakes gradually, or dis-ediately on the uphill side.

WARNING

ARD ackwards or improper-hile climbing a hill.

PEN TV overturning. THE HAZARD r and maintain steadybing a hill. ward speed: phill. es. rking position “P” afterd.


7-28

If your ATV has stalled or stopped and youbelieve you can continue up the hill, restartcarefully to make sure you do not lift the frontwheels which could cause you to lose control.If you are unable to continue up the hill, dis-mount the ATV on the uphill side. Physicallyturn the ATV around and then descend thehill.

If you start to roll backwards, DO NOT applyeither brake abruptly. If you are in 2WD, applyonly the front brake. When this ATV is in 4WDor 4WD-LOCK, all wheels (front and rear) areinterconnected by the drive train. This meansthat applying either the front brake or the rearbrake will brake all wheels. When descendinghills, using either brake lever or the brake ped-al will brake the wheels on the downhill side.Avoid sudden application of either the front orrear brake because the wheels on the uphillside could come off the ground. The ATVcould easily tip over backwards. Apply both

the front and rearmount the ATV imm

POTENTIAL HAZStalling, rolling bly dismounting wWHAT CAN HAPCould result in AHOW TO AVOID Use proper geaspeed when climIf you lose all for

Keep weight uApply the brakShift to the payou are stoppe


7-29

If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brakewhile rolling backwards. Apply thefront brake. When fully stopped, shiftto the parking position “P”. 4WD or 4WD-LOCK: Apply both frontand rear brakes gradually. When fullystopped, shift to the parking position“P”.

Dismount on uphill side or to a side ifpointed straight uphill. Turn the ATVaround and remount, following the pro-cedure described in the Owner’s Manu-al.

n 4WD or 4WD-LOCK, allear) are interconnected by means that applying eitherhe rear brake will brake allcending hills, using eitherbrake pedal will brake thenhill side. Avoid sudden

the front or rear brake be- on the uphill side couldd. Apply both the front andlly.

, ride your ATV straightrp angles which could al-

ip or roll over. Carefullynd ride no faster than yout to obstacles which may


7-30

RIDING DOWNHILL When riding your ATV downhill, shift yourweight as far to the rear and uphill side of theATV as possible. Move back on the seat andsit with your arms straight. Engine compres-sion will do most of the braking for you. Formaximum engine compression braking effect,select low range “L” and change to 4WD or4WD-LOCK before beginning to descend thehill. Improper braking may cause a loss oftraction. Use caution while descending a hillwith loose or slippery surfaces. Braking abilityand traction may be adversely affected bythese surfaces. Improper braking may alsocause a loss of traction.

When this ATV is iwheels (front and rthe drive train. Thisthe front brake or twheels. When desbrake lever or the wheels on the dowapplication of eithercause the wheelscome off the grounrear brakes gradua

Whenever possibledownhill. Avoid shalow the ATV to tchoose your path awill be able to reacappear.


7-31

WARNING

POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause theATV to overturn. Always follow proper procedures for go-ing down hills as described in this Own-er’s Manual. Note: a special technique isrequired when braking as you go downa hill. HOW TO AVOID THE HAZARD Always check the terrain carefully be-fore you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle thatwould cause the vehicle to lean sharplyto one side. Go straight down the hillwhere possible.

WARNING

ARD ing hills or turning on

PEN of control or cause the

THE HAZARD turn the ATV around

you have mastered thee as described in the

l on level ground. Been turning on any hill.he side of a steep hill if

he side of a hill: oper procedures as de-ner’s Manual.

excessively slippery orhift your weight to the

ATV.


7-32

CROSSING A SLOPE Traversing a sloping surface on your ATV re-quires you to properly position your weight tomaintain proper balance. Be sure that youhave learned the basic riding skills on flatground before attempting to cross a slopingsurface. Avoid slopes with slippery surfacesor rough terrain that may upset your balance.

As you travel across a slope, lean your bodyin the uphill direction. It may be necessary tocorrect the steering when riding on loose sur-faces by pointing the front wheels slightly up-hill. When riding on slopes be sure not tomake sharp turns either up or down hill.

If your ATV does begin to tip over, graduallysteer in the downhill direction if there are noobstacles in your path. As you regain properbalance, gradually steer again in the directionyou wish to travel.

POTENTIAL HAZImproperly crosshills. WHAT CAN HAPCould cause lossATV to overturn.HOW TO AVOID Never attempt toon any hill until turning techniquOwner’s Manuavery careful whAvoid crossing tpossible. When crossing tAlways follow prscribed in the OwAvoid hills with loose surfaces. Suphill side of the


7-33

et brakes may have re-bility. Test your brakes

ter. If necessary, applyes to let friction dry out


7-34

CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving,shallow water of up to a maximum of 35 cm(14 inches) in depth. Before entering the wa-ter, choose your path carefully. Enter wherethere is no sharp drop off, and avoid rocks orother obstacles which may be slippery or up-set the ATV. Drive slowly and carefully.

WARNING

POTENTIAL HAZARD Operating this ATV through deep or fastflowing water. WHAT CAN HAPPEN Tires may float, causing loss of tractionand loss of control, which could lead toan accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowingwater or in water deeper than that spec-ified in your Owner’s Manual.

Remember that wduced stopping aafter leaving wathem several timthe linings.

ATV in water, be sure to water by removing thee bottom of the air filterooling duct check hose,

ever box check hose andartment check hose. Also,t case drain plug to drainmay have accumulated. fresh water if it has beenater or muddy conditions.

ose


7-35

Test your brakes after leaving the water. Donot continue to ride your ATV without verifyingthat you have regained proper braking ability.

CAUTION:_

After riding yourdrain the trappedcheck hose at thcase, the V-belt cthe drive select lthe storage compremove the V-belany water that Wash the ATV inoperated in salt w_

1. Air filter case check h

check hose


7-36

1. V-belt cooling duct check hose (left front side of ATV)

1. Drive select lever box check hose

1. Storage compartment

1. V-belt case drain plug

WARNING

ZARD ating over obstacles. PEN

ss of control or a colli-se the ATV to overturn. THE HAZARD g in a new area, check

o ride over large obsta-ge rocks or fallen trees. er obstacles, always fol-edures as described in

nual.


7-37

RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done withcaution. Look out for obstacles which couldcause damage to the ATV or could lead to anupset or accident. Be sure to keep your feetfirmly mounted on the footboards at all times.Avoid jumping the ATV as loss of control anddamage to the ATV may result.

POTENTIAL HAImproperly operWHAT CAN HAPCould cause losion. Could cauHOW TO AVOIDBefore operatinfor obstacles. Never attempt tcles, such as larWhen you go ovlow proper procthe Owner’s Ma

of your ATV start to slidean usually be regained (ifso) by steering in the direc-plying the brakes or accel-mmended until you have


7-38

SLIDING AND SKIDDING Care should be used when riding on loose orslippery surfaces since the ATV may slide. Ifunexpected and uncorrected, sliding couldlead to an accident.

To reduce the tendency for the front wheels toslide in loose or slippery conditions, position-ing your weight over the front wheels willsometimes help.

If the rear wheels sideways, control cthere is room to do tion of the slide. Aperating is not recocorrected the slide.

WARNING

ZARD ing improperly. PEN ontrol of this ATV. You traction unexpectedly,e the ATV to overturn. THE HAZARD control skidding or slid-g at low speeds and onrrain. ippery surfaces, such asnd be very cautious in

the chance of skidding control.


7-39

With practice, over a period of time, skill atcontrolled sliding can be developed. The ter-rain should be chosen carefully before at-tempting such maneuvers, since both stabilityand control are reduced. Bear in mind thatsliding maneuvers should always be avoidedon extremely slippery surfaces such as ice,since all control may be lost.

POTENTIAL HASkidding or slidWHAT CAN HAPYou may lose cmay also regainwhich may causHOW TO AVOIDLearn to safely ing by practicinlevel, smooth teOn extremely slice, go slowly aorder to reduceor sliding out of

s to slide sideways: tion of the slide if you haveng the brakes or accelerat-

ended until you have cor-(See pages 7-38–7-39.) t make it up a hill you are

round if you still have for-ot, stop, dismount on the ATV and physically turn. If the ATV starts to slipNOT USE THE REARV may tip over on top ofe ATV on the uphill side.

–7-29.)


7-40

WHAT TO DO IF ... This section is designed to be a referenceguide only. Be sure to read each section onriding techniques completely.

WHAT TO DO ... � If your ATV doesn’t turn when you want it

to: Bring the ATV to a stop and practice theturning maneuvers again. Be sure you areputting your weight on the footboard to theoutside of the turn. Position your weightover the front wheels for better control.(See pages 7-22–7-23.)

� If your ATV begins to tip while turning: Lean more into the turn to regain balance. Ifnecessary, gradually let off the throttle and/or steer to the outside of the turn. (Seepages 7-22–7-23.)

� If your ATV startSteer in the directhe room. Applyiing is not recommrected the slide.

� If your ATV can’trying to climb: Turn the ATV award speed. If nuphill side of thethe ATV aroundbackwards DO BRAKE - the ATyou. Dismount th(See pages 7-24

ntial hazard that couldinjury or death.


7-41

� If your ATV is traversing a sloping surface: Be sure to ride with your weight positionedtowards the uphill side of the ATV to main-tain proper balance. If the ATV starts to tip,steer down the hill (if there are no obstaclesin your way) to regain balance. If you dis-cover that the ATV is going to tip over, dis-mount on the uphill side. (See pages 7-32–7-33.)

� If your ATV encounters shallow water: Ride slowly and carefully through slowmoving water, watching for obstacles. Besure to let water drain from the ATV andCHECK YOUR BRAKES FOR PROPEROPERATION when you come out of thewater. Do not continue to ride your ATV un-til you have regained adequate brakingability. (See pages 7-34–7-36.)

WARNING_

Indicates a poteresult in serious

EBU00515

nd tool kitnded to put this owner’sbag and always carry it onat as shown. Put the own-

-pressure tire gauge under

e

ealer perform service ifiliar with machine ser-


8-1

1-PERIODIC MAINTENANCE AND ADJUSTMENT

Periodic inspection, adjustment and lubrica-tion will keep your machine in the safest andmost efficient condition possible. Safety is anobligation of the machine owner. The mostimportant points of machine inspection, ad-justment and lubrication are explained on thefollowing pages.

EBU14510

Owner’s manual aYou are recommemanual in the vinyl the bottom of the seer’s tool kit and lowthe seat.

1. Owner’s manual2. Owner’s tool kit3. Low-pressure tire gaug

WARNING

POTENTIAL HAZARDServicing an engine while it is running.WHAT CAN HAPPENMoving parts can catch clothing or partsof the body, causing injury.Electrical components can causeshocks or can start fires.HOW TO AVOID THE HAZARDTurn off the engine when performingmaintenance unless otherwise speci-fied.

Have a Yamaha dyou are not famvice.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

WARNING

ZARD TV with improper modi-

PEN lation of accessories orthis vehicle may causeling which in some situ-d to an accident. THE HAZARD is ATV through improp-r use of accessories. Allsories added to this ve-e genuine Yamaha orponents designed for and should be installedrding to instructions. Ifions, consult an autho-TV dealer.


8-2

The service information included in this man-ual is intended to provide you, the owner, withthe necessary information for completing yourown preventive maintenance and minor re-pairs. The tools provided in the Owner’s toolkit are sufficient for this purpose, except that atorque wrench is also necessary to properlytighten nuts and bolts.

NOTE:_

If you do not have a torque wrench availableduring a service operation requiring one, takeyour machine to a Yamaha dealer to checkthe torque settings and adjust them as neces-sary. _

POTENTIAL HAOperating this Afications. WHAT CAN HAPImproper instalmodification of changes in handations could leaHOW TO AVOIDNever modify ther installation oparts and acceshicle should bequivalent comuse on this ATVand used accoyou have questrized Yamaha A

EBU02611

intenance intervals. urs maintenance intervals. How-maintenance intervals should be

INITIAL EVERY3 6 6 12

1,200 (750)

2,400 (1,500)

2,400 (1,500)

4,800 (3,000)

75 150 150 300

Every 20–40 hoursore often in wet or dusty areas.)


8-3

PERIODIC MAINTENANCE/LUBRICATION

NOTE:_

� For ATVs not equipped with an odometer or an hour meter, follow the month ma� For ATVs equipped with an odometer or an hour meter, follow the km (mi) or ho

ever, keep in mind that if the ATV isn’t used for a long period of time, the month followed.

_

ITEM ROUTINEWhichever comes first

month 1km(mi)

320 (200)

hours 20

Valves* • Check valve clearance. • Adjust if necessary.

Cooling system• Check coolant leakage.• Repair if necessary.• Replace coolant every 24 months.

Spark plug• Check condition. • Adjust gap and clean.• Replace if necessary.

Air filter element • Clean. • Replace if necessary. (M

Carburetor* • Check starter (choke).• Adjust engine idling speed.

Crankcase breather system*

• Check breather hose for cracks or damage.• Replace if necessary.

Exhaust system*• Check for leakage.• Tighten if necessary.• Replace gasket(s) if necessary.

Spark arrester • Clean.


1,200 (750)

2,400 (1,500)

2,400 (1,500)

4,800 (3,000)

75 150 150 300


8-4

Fuel line* • Check fuel hose for cracks or damage.• Replace if necessary.

Engine oil • Replace. (Warm engine before draining.)Engine oil filter cartridge • Replace.Engine oil strainer* • Clean.Final gear oil • Check oil level/oil leakage.

• Replace every 12 months.Differential gear oil

Front brake* • Check operation/fluid leakage. (See NOTE page 8-5.)• Correct if necessary.

Rear brake* • Check operation/fluid leakage. (See NOTE page 8-5.)• Correct if necessary.

Select lever safety system cable*

• Check operation. • Adjust if necessary.

V-belt* • Check operation. • Check for cracks or damage.

Wheels* • Check balance/damage/runout. • Repair if necessary.

Wheel bearing* • Check bearing assemblies for looseness/damage.• Replace if damaged.

Front and rear suspension*

• Check operation.• Correct if necessary.

Steering system* • Check operation./Replace if damaged.• Check toe-in./Adjust if necessary.

Rear upper and lower knuckle pivots* • Lubricate with lithium-soap-based grease.

Drive shaft universal joint* • Lubricate with lithium-soap-based grease.Engine mount* • Check for cracks or damage.

Front and rear axle boots* • Check operation.• Replace if damaged.


month 1km(mi)

320 (200)

hours 20

vice.

ntial hazard that couldjury or death.


1,200 (750)

2,400 (1,500)

2,400 (1,500)

4,800 (3,000)

75 150 150 300


8-5

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser

NOTE:� Recommended brake fluid: DOT 4� Brake fluid replacement:

• When disassembling the master cylinders or cal-ipers, replace the brake fluid. Normally check thebrake fluid level and add fluid as required.

• On the inner parts of the master cylinders andcalipers, replace the oil seals every two years.

• Replace the brake hoses every four years, or ifcracked or damaged.

WARNING_

Indicates a poteresult in serious in

Stabilizer bushes* • Check for cracks or damage.

Fittings and fasteners* • Check all chassis fittings and fasteners.• Correct if necessary.

Lights and switches* • Check operation.• Adjust headlight beams.


month 1km(mi)

320 (200)

hours 20

2. Panel D4. Panel F


8-6

EBU00614

Panel removal and installationThe panels illustrated need to be removed toperform some of the maintenance describedin this chapter.Refer to this section each time a panel has tobe removed or reinstalled.

1. Panel A 2. Panel B

1. Panel C3. Panel E

EBU00700


8-7

Panel A, DTo remove1. Remove the seat.2. Pull outward on the areas shown, and

then pull upward.


8-8

To install1. Place the panel in its original position.2. Install the seat.

EBU01147 EBU15370

p carrier bolts.

rrier bolts under the fend-ake the carrier off.


8-9

Panel BTo removeRemove the bolt, and then take the panel off.To installPlace the panel in the original position and in-stall the bolt.

CAUTION:_

When installing the panel, be sure not topinch the cables or wires. _

1. Bolt 2. Panel B

Panel CTo remove1. Remove the to

1. Carrier bolt (× 4) (top)

2. Remove the caers, and then t

nel in the original position,stall the quick fastener

rier in the original position,ll the carrier bolts under the

carrier bolts, and then tight- the specified torques.

e:p):

m·kgf, 25 ft·lbf)nder fenders):·kgf, 5.1 ft·lbf)


8-10

1. Bolt (× 2) (under fenders)

3. Remove the quick fastener screws, andthen pull the panel upward to remove.

1. Quick fastener screw (× 2) 2. Panel C

To install1. Place the pa

and then inscrews.

2. Place the carand then instafenders.

3. Install the top en all bolts to

Tightening torquCarrier bolt (to

34 Nm (3.4Carrier bolt (u

7 Nm (0.7 m

EBU01013 EBU00638

areas shown.


8-11

Panel ETo removeRemove the bolts, and then take the panel off.To installPlace the panel in the original position, andthen install the bolts.

1. Panel E 2. Bolt (× 3)

Panel FTo removePull outward on the

1. Panel F

l filter cartridgel should be checked beforeon, the oil must be changedrtridge replaced at the inter-the periodic maintenancert.

ine oil levelel F. (See page 8-11 foral and installation proce-

on a level surface.ine, warm it up for severalthen turn it off.nutes until the oil settles.ngine oil filler cap and wipe

k with a clean rag.


8-12

To installPlace the panel in its original position.

EBU10992

Engine oil and oiThe engine oil leveeach ride. In additiand the oil filter cavals specified in and lubrication cha

To check the eng1. Remove pan

panel removdures.)

2. Place the ATV3. Start the eng

minutes, and 4. Wait a few mi5. Remove the e

off the dipstic

2. Minimum level mark

il is at or below the mini-rk, add sufficient oil of the type to raise it to the cor-

tick into the oil filler hole,n the oil filler cap.l.


8-13

1. Engine oil filler cap

6. Insert the dipstick in the oil filler hole(without screwing it in), and then removeit again to check the oil level.

NOTE:_

The engine oil should be between the mini-mum and maximum level marks. _

1. Maximum level mark

7. If the engine omum level marecommendedrect level.

8. Insert the dipsand then tighte

9. Install the pane

the oil filter cartridge is not

els D and E. (See pages for panel removal and in-edures.)il filter cartridge with an oil

ge


8-14

To change the engine oil (with or withoutoil filter cartridge replacement)1. Remove panel F. (See page 8-11 for

panel removal and installation proce-dures.)

2. Start the engine, warm it up for severalminutes, and then turn it off.

3. Place an oil pan under the engine to col-lect the used oil, and then remove the en-gine oil filler cap.

4. Remove the engine oil drain bolt to drainthe oil from the crankcase.

1. Engine oil drain bolt

NOTE:_

Skip steps 5–9 if being replaced. _

5. Remove pan8-7–8-8, 8-11stallation proc

6. Remove the ofilter wrench.

1. Engine oil filter cartrid

oil filter cartridge with an and then tighten it to the with a torque wrench.

e:·kgf, 12 ft·lbf)


8-15

1. Oil filter wrench

NOTE:_

An oil filter wrench is available at a nearbyYamaha dealer. _

7. Apply a light coat of engine oil to theO-ring of the new oil filter cartridge.

NOTE:_

Make sure the O-ring is seated properly. _

1. O-ring

8. Install the new oil filter wrench,specified torque

Tightening torque:Oil filter cartridg

17 Nm (1.7 m

prevent clutch slippagengine oil also lubricatesdo not mix any chemical not use oils with a diesel of “CD” or oils of a high-an specified. In addition, oils labeled “ENERGYG II” or higher. at no foreign material en-kcase.

engine oil:.

r cartridge replacement: Imp qt, 2.43 US qt)artridge replacement: Imp qt, 2.54 US qt)


8-16

1. Torque wrench

9. Install panels E and D.10. Install the engine oil drain bolt, and then

tighten it to the specified torque.

11. Add the specified amount of recommend-ed engine oil, and then install the engineoil filler cap and tighten it.

CAUTION:_

� In order to (since the ethe clutch), additives. Dospecificationer quality thdo not useCONSERVIN

� Make sure thters the cran

_

Tightening torque:Engine oil drain bolt:

23 Nm (2.3 m·kgf, 16 ft·lbf)

Recommended See page 10-2

Oil quantity:Without oil filte

2.30 L (2.02With oil filter c

2.40 L (2.11

EBU15380

l gear oil level on a level surface.il filler bolt, and then checkthe final gear case.

be at the brim of the filler

w the brim of the filler hole,oil of the recommendedto the correct level.

2. Correct level


8-17

12. Start the engine and warm it up for seve-ral minutes. While warming up, check foroil leakage. If oil leakage is found, turnthe engine off immediately and check forthe cause.

13. Turn the engine off, and then check theoil level and correct it if necessary.

14. Install panel F.

Final gear oil Checking the fina1. Place the ATV2. Remove the o

the oil level in

NOTE:_

The oil level shouldhole. _

3. If the oil is beloadd sufficient type to raise it

1. Final gear oil drain bolt3. Final gear oil

al gear oilengine guard and the finalrd by removing the bolts.

2. Final gear case guard

on a level surface.ainer under the final geart the used oil.


8-18

CAUTION:_

Be sure no foreign material enters the finalgear case. _

4. Install the oil filler bolt, and then tighten itto the specified torque.

Changing the fin1. Remove the

gear case gua

1. Engine guard3. Bolt (× 11)

2. Place the ATV3. Place a cont

case to collec

Tightening torque:Final gear oil filler bolt:

23 Nm (2.3 m·kgf, 16 ft·lbf)

mended final gear oil to filler hole.

material enters the final

ller bolt, and then tighten it torque.

leakage. If oil leakage isr the cause.

il:-4 Hypoid gear oil

p qt, 0.24 US qt)

:ller bolt:

·kgf, 16 ft·lbf)


8-19

4. Remove the oil filler bolt and the drainbolt to drain the oil.

1. Final gear oil drain bolt

5. Install the drain bolt, and then tighten it tothe specified torque.

6. Add the recomthe brim of the

CAUTION:_

Be sure no foreigngear case. _

7. Install the oil fito the specified

8. Check for oil found, check fo

Tightening torque:Final gear oil drain bolt:

23 Nm (2.3 m·kgf, 16 ft·lbf)

Recommended oSAE 80 API GL

Oil quantity:0.23 L (0.20 Im

Tightening torqueFinal gear oil fi

23 Nm (2.3 m

ilerential gear oil on a level surface.ifferential gear oil filler bolt oil level. It should be up toe filler hole. If the level is

cient oil of the recommend-e it to the specified level.

er bolt


8-20

9. Install the engine guard and the final gearcase guard by installing the bolts, andthen tightening them to the specifiedtorques.

EBU07063

Differential gear oChecking the diff1. Place the ATV2. Remove the d

and check thethe brim of thlow, add suffied type to rais

1. Differential gear oil2. Differential gear oil fill3. Specified level

Tightening torques:Engine guard bolt:

7.0 Nm (0.7 m·kgf, 5.1 ft·lbf)Final gear case guard bolt:

7.0 Nm (0.7 m·kgf, 5.1 ft·lbf)

in bolt

rential gear oil drain bolto the specified torque.

tial gear case with the rec-.

:r oil drain bolt:·kgf, 7.2 ft·lbf)


8-21

CAUTION:_

Be sure no foreign material enters the dif-ferential gear case. _

3. Install the differential gear oil filler bolt,and then tighten it to the specified torque.

Replacing the differential gear oil1. Place the ATV on a level surface.2. Place a container under the differential

gear case to collect the used oil.3. Remove the differential gear oil filler bolt

and differential gear oil drain bolt to drainthe oil.

1. Differential gear oil dra

4. Install the diffeand tighten it t

5. Fill the differenommended oil

Tightening torque:Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 16 ft·lbf)

Tightening torqueDifferential gea

10 Nm (1.0 m

on a level surface.olant level in the coolantn the engine is cold as thewill vary with engine tem-

d be between the minimuml marks.



8-22

CAUTION:_

Be sure no foreign material enters the dif-ferential gear case. _

6. Install the differential gear oil filler bolt,and then tighten it to the specified torque.

7. Check for oil leakage. If oil leakage isfound, check for the cause.

EBU12560

Cooling system1. Place the ATV2. Check the co

reservoir whecoolant level perature.

NOTE:_

The coolant shouland maximum leve_

1. Coolant reservoir cap2. Maximum level mark

Recommended oil:SAE 80 API GL-4 Hypoid gear oil

Oil quantity:0.23 L (0.20 Imp qt, 0.24 US qt)

Tightening torque:Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 16 ft·lbf)

ed, have a Yamaha dealerfreeze content of the cool- possible. n operation is completely

switched on or off accord-nt temperature in the radi-

ats, see page 8-62 for de-


8-23

3. If the coolant is at or below the minimumlevel mark, remove panel D (See pages8-7–8-8, 8-11 for panel removal and in-stallation procedures.), remove the reser-voir cap, add coolant to the maximumlevel mark, install the reservoir cap, andthen install the panel.

CAUTION:_

Hard water or salt water is harmful to theengine. You may use soft water if you can-not get distilled water. _

NOTE:_

� If water is addcheck the antiant as soon as

� The radiator faautomatic. It ising to the coolaator.

_

If your ATV overhetails.

Coolant reservoir capacity (up to the maximum level mark):

0.25 L (0.22 Imp qt, 0.26 US qt)

on a level surface.els E and F. (See pages panel removal and installa-s.)iner under the engine, andthe coolant drain bolt. (Use similar object as shown tont from spilling on the foot-


8-24

EBU12572

Changing the coolant 1. Place the ATV2. Remove pan

8-11–8-12 fortion procedure

3. Place a contathen remove a trough or aprevent coolarest.)

1. Coolant drain bolt

WARNING

POTENTIAL HAZARD Removing the radiator cap when the en-gine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid andsteam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before re-moving the radiator cap. Always use athick rag over the cap. Allow any re-maining pressure to escape beforecompletely removing the cap.

D. (See pages 8-7–8-8 forl and installation proce-

olant reservoir cap. hose on the coolant res-d then drain the coolant

nt reservoir.


8-25

1. Trough

4. Remove the front carrier and panel C.(See pages 8-9–8-10 for removal and in-stallation procedures.)

5. Remove the radiator cap.

1. Radiator cap

6. Remove panelpanel removadures.)

7. Remove the co8. Disconnect the

ervoir side, anfrom the coola

lant reservoir hose.mmended coolant into thee maximum level mark, and reservoir cap and panel D.mmended coolant into thet is full, and then install the

antifreeze:thylene glycol antifreeze rosion inhibitors for ines.ater mixing ratio:

p qt, 1.37 US qt)ir capacity um level mark):p qt, 0.26 US qt)


8-26

1. Coolant reservoir hose

9. After draining the coolant, thoroughlyflush the cooling system with clean tapwater.

10. Replace the coolant drain bolt washer if itis damaged, install the coolant drain bolt,and then tighten it to the specified torque.

11. Install the coo12. Pour the reco

reservoir to ththen install the

13. Pour the recoradiator until iradiator cap.

Tightening torque:Coolant drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Recommended High quality econtaining coraluminum eng

Antifreeze and w1:1

Total amount:1.30 L (1.14 Im

Coolant reservo(up to the maxim

0.25 L (0.22 Im

EBU00862

e boots for holes or tears.und, have them replacedr.

ch side)


8-27

CAUTION:_

Hard water or salt water is harmful to theengine. You may use soft water if you can-not get distilled water. _

14. Start the engine and let it idle for severalminutes. Stop the engine, and thencheck the coolant level in the radiator. If itis low, add more coolant until it reachesthe top of the radiator.

15. Check for coolant leakage.

NOTE:_

If any leakage is found, have a Yamaha deal-er check the cooling system. _

16. Install the panels and the front carrier.

Axle bootsCheck the protectivIf any damage is foby a Yamaha deale

1. Front axle boot (× 2 ea

ction

l A. (See pages 8-7–8-8 foral and installation proce-

park plug cap.


8-28

1. Rear axle boot (× 2 each side)

EBU00864

Spark plug inspeRemoval1. Remove pane

panel removdures.)

2. Remove the s

1. Spark plug cap

diagnose such problems

TV to a Yamaha dealer.ically remove and inspectuse heat and deposits willlug to slowly break downode erosion becomes ex-n and other deposits areuld replace the spark pluglug.

electrode gap with a wiree and, if necessary, adjust

cification.

lug:

.024–0.028 in)


8-29

3. Use the spark plug wrench in the tool kitto remove the spark plug as shown.

1. Spark plug wrench

Inspection The spark plug is an important engine compo-nent and is easy to inspect. The condition ofthe spark plug can indicate the condition ofthe engine. The ideal color on the white insulator aroundthe center electrode is a medium-to-light tancolor for a ATV that is being ridden normally.

Do not attempt toyourself. Instead, take the AYou should periodthe spark plug becacause the spark pand erode. If electrcessive, or if carboexcessive, you showith the specified p

Installation 1. Measure the

thickness gaugthe gap to spe

Specified spark pDR8EA (NGK)

Spark plug gap: 0.6–0.7 mm (0

is not available when yourk plug, a good estimate ofis 1/4 to 1/2 turn past fingerpark plug tightened to the soon as possible.

rk plug cap.el.


8-30

a. Spark plug gap

2. Clean the gasket surface. Wipe off anygrime from the threads.

3. Install the spark plug and tighten it to thespecified torque.

NOTE:_

If a torque wrenchare installing a spathe correct torque tight. Have the sspecified torque as_

4. Install the spa5. Install the pan

Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)

EBU15140

2. Air filter case cover

ir filter element assembly.

bly


8-31

Air filter element cleaning

NOTE:_

There is a check hose at the bottom of the airfilter case. If dust or water collects in thishose, empty the hose and clean the air filterelement and air filter case. _

1. Air filter case check hose

1. Remove the seat. (See pages 4-20–4-21for seat removal and installation proce-dures.)

2. Remove the air filter case cover by un-hooking the fasteners.

1. Fastener (× 4)

3. Remove the a

1. Air filter element assem

xcess solvent out of the airand let it dry.

air filter element when

r filter element and replace

WARNING

ZARD point solvents or gaso- air filter element. PEN

solvents or gasoline canlode. THE HAZARD ing solvent to clean thet.


8-32

4. Pull off the lock plate, and then removethe air filter element from its frame.

1. Air filter element frame 2. Air filter element3. Lock plate

5. Wash the element gently but thoroughlyin solvent.

6. Squeeze the efilter element

CAUTION:_

Do not twist thesqueezing it. _

7. Inspect the aiit if damaged.

POTENTIAL HAUsing low flashline to clean theWHAT CAN HAPLow flash point catch fire or expHOW TO AVOIDUse parts cleanair filter elemen

t should be cleaned everyuld be cleaned and lubri-

the machine is operated inas. Each time the air filterce is performed, check theer case for obstructions.ase rubber joint to the car-old fittings for an airtightings securely to avoid theed air entering the engine.

engine with the air filter This will allow unfilteredg rapid engine wear and

amage. Additionally, op-e air filter element will af-etting with subsequente and possible engine


8-33

8. Apply Yamaha foam air filter oil or otherquality foam air filter oil to the air filter el-ement.

NOTE:_

The air filter element should be wet but notdripping. _

9. Pull the air filter element over its frame,and then install the lock plate.

10. Install the air filter element assembly.11. Install the air filter case cover by hooking

the fasteners onto the air filter case.12. Install the seat.

NOTE:_

The air filter elemen20–40 hours. It shocated more often if extremely dusty areelement maintenanair inlet to the filtCheck the air filter cburetor and manifseal. Tighten all fittpossibility of unfilter_

CAUTION:_

Never operate theelement removed.air to enter, causinpossible engine deration without thfect carburetor jpoor performancoverheating. _

plugr deep enough to allow it to

case, remove this plug tom the case.

m the V-belt case after re-have a Yamaha dealer in-the water may affect other


8-34

EBU06411

V-belt cooling duct check hoseIf dust or water collects in the V-belt coolingduct check hose, remove the hose and cleanit.

1. V-belt cooling duct check hose (left front side of ATV)

EBU08741

V-belt case drainAfter riding in wateenter the V-belt drain the water fro

NOTE:_

If water drains fromoving the plug, spect the ATV as engine parts. _

1. V-belt case drain plug

EBU01066

2. Spark arrester

pipe into the muffler andoles.ten the bolts.


8-35

Spark arrester cleaningBe sure the exhaust pipe and muffler are coolbefore cleaning the spark arrester.1. Remove the bolts.2. Remove the tailpipe by pulling it out of

the muffler.

1. Bolt (× 3) 2. Tailpipe

3. Tap the tailpipe lightly, and then use awire brush to remove any carbon depos-its from the spark arrester portion of thetailpipe.

1. Tailpipe

4. Insert the tailalign the bolt h

5. Install and tigh

tment vital part of the engine andisticated adjustment. Moste left to a Yamaha dealerssional knowledge and ex- However, the idling speed by the owner as a part ofnce routine.

as set at the Yamaha fac-tests. If the settings are

eone without sufficientdge, poor engine perfor-ge may result.


8-36

EBU00296

Carburetor adjusThe carburetor is arequires very sophadjusting should bwho has the profeperience to do so.may be performedthe usual maintena

CAUTION:The carburetor wtory after many disturbed by somtechnical knowlemance and dama

WARNING

POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust systemWHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poison-ing, possibly leading to death. Could start a fire.HOW TO AVOID THE HAZARD When cleaning the spark arrester:Always let the exhaust system cool pri-or to touching exhaust components. Do not start the engine when cleaningthe exhaust system.

EBU12580

chometer to the spark plug set the idle to the specified adjusting the throttle stope screw in direction a tongine speed, and in direc-ease the engine speed.

l.

ed: min


8-37

Idle speed adjustment

NOTE:_

A diagnostic tachometer must be used for thisprocedure. _

1. Start the engine and warm it up for a fewminutes at approximately 1,000 to2,000 r/min. Occasionally rev the engineto 4,000 to 5,000 r/min. The engine iswarm when it quickly responds to thethrottle.

2. Remove panel D. (See pages 8-7–8-8 forremoval and installation procedures.)

3. Connect the talead, and thenidling speed byscrew. Turn thincrease the etion b to decr

1. Throttle stop screw

4. Install the pane

Specified idle spe1,450–1,550 r/

ustment

idling speed before adjust-r free play.

cknut.ting bolt until the throttle le-

y is 3.0–5.0 mm (0.12–

cknut.

2. Adjusting bolty


8-38

EBU00303

Valve clearance adjustmentThe correct valve clearance changes withuse, resulting in improper fuel/air supply orengine noise. To prevent this, the valve clear-ance must be adjusted regularly. This adjust-ment however, should be left to a professionalYamaha service technician.

EBU00307

Throttle lever adj

NOTE:Adjust the engine ing the throttle leve

1. Loosen the lo2. Turn the adjus

ver free pla0.20 in).

3. Tighten the lo

1. Locknuta. Throttle lever free pla

EBU03050 EBU13090

heck ds for damage and wear.ness is less than 1.0 mm

amaha dealer replace the

be removed to check theages 8-49–8-50 for remov-rocedures.)


8-39

Select lever safety system cable adjustmentThe select lever safety system cable stretch-es with use, resulting in improper function. Toprevent this, the cable must be adjusted regu-larly. This adjustment, however, should be leftto a Yamaha dealer.

Front brake pad cCheck the brake paIf a brake pad thick(0.04 in), have a Ypads as a set.

a. Brake pad thickness

NOTE:_

The wheels need tobrake pads. (See pal and installation p_

to be removed to check thepages 8-49–8-50 for wheellation procedures.)


8-40

EBU06212

Rear brake pad checkCheck the brake pads for damage or wear.Wear indicator grooves are provided on thebrake pads. These indicators allow checkingof brake pad wear without disassembling thebrake. Check the wear indicator grooves. If abrake pad has worn to the point that the wearindicator grooves have almost disappeared,ask a Yamaha dealer to replace the pads as aset.

1. Brake pad wear indicator groove

NOTE:_

The wheels need brake pads. (See removal and instal_

EBU06221


8-41

Inspecting the brake fluid levelInsufficient brake fluid may let air enter thebrake system, possibly causing the brakes tobecome ineffective.Before riding, check that the brake fluid isabove the minimum level mark and replenishwhen necessary. A low brake fluid level mayindicate worn brake pads and/or brake sys-tem leakage. If the brake fluid level is low, besure to check the brake pads for wear and thebrake system for leakage. The rear brake fluidmaster cylinder reservoir is located underpanel C. (See pages 8-9–8-10 for panel re-moval and installation procedures.)



FRONT

REAR

deteriorate painted surfac-rts. Always clean up spilledy. dealer check the cause ifvel goes down.

ement lacement should be doneamaha service personnel.ealer replace the followingg periodic maintenance oraged or leaking.

seals every two years. ke hoses every four years.


8-42

Observe these precautions:� When checking the fluid level, make sure

the top of the master cylinder reservoirs arelevel.

� Use only the designated quality brake fluid.Otherwise, the rubber seals may deterio-rate, causing leakage and poor brake per-formance.

� Refill with the same type of brake fluid. Mix-ing fluids may result in a harmful chemicalreaction and lead to poor brake perfor-mance.

� Be careful that water does not enter themaster cylinder reservoirs when refilling.Water will significantly lower the boilingpoint of the fluid and may result in vaporlock.

� Brake fluid mayes or plastic pafluid immediatel

� Have a Yamahathe brake fluid le

EBU11860

Brake fluid replacComplete fluid reponly by trained YHave a Yamaha dcomponents durinwhen they are dam� Replace the oil � Replace the bra

Recommended brake fluid: DOT 4

EBU11870

WARNING

ARD improperly serviced or PEN braking ability, which

accident. THE HAZARD

the brakes operated that the free play is

e brakes do not drag. the brakes are not

air must be bled fromstem. brake components re-nal knowledge. These

uld be performed by a


8-43

Front brake lever free playThe front brake lever should have a free playof zero mm (zero in) at the lever end. If not,have a Yamaha dealer check the brake sys-tem.

a. Front brake lever free play

POTENTIAL HAZOperating with adjusted brakes.WHAT CAN HAPYou could lose could lead to an HOW TO AVOID After servicing:

� Make sure smoothly ancorrect.

� Make sure th� Make sure

spongy. All the brake sy

Replacement of quires professioprocedures shoYamaha dealer.

cannot be obtained, ask amake that adjustment.

e rear brake lever free play: step on the brake pedal.

he brake pedal does not


8-44

EBU09631

Adjusting the rear brake lever and brake pedal Adjusting the rear brake lever The rear brake lever free play should be 0.5–2.0 mm (0.02–0.08 in).1. Loosen the locknut.

1. Locknut 2. Adjusting boltc. Rear brake lever free play

2. Turn the adjusting bolt in direction a toincrease free play, and in direction b todecrease free play.

3. Tighten the locknut.

If correct free playYamaha dealer to

NOTE:_

When adjusting th� Be sure not to� Make sure t

move. _

WARNING

ARD improperly serviced or PEN braking ability, which

accident. THE HAZARD

the brakes operatethat the free play is cor-

brakes do not drag. e bled from the brake

brake components re-nal knowledge. These

uld be performed by a


8-45

Adjusting the brake pedalThe top of the brake pedal should be posi-tioned 72 mm (2.83 in) above the top of thefootrest. If not, ask a Yamaha dealer to adjustit.

a. Brake pedal position

POTENTIAL HAZOperating with adjusted brakes.WHAT CAN HAPYou could lose could lead to an HOW TO AVOID After servicing: � Make sure

smoothly and rect.

� Make sure the� All air must b

system. Replacement of quires professioprocedures shoYamaha dealer.

sting nut while holding theht switch in place. To maket come on earlier, turn the

in direction a. To make theme on later, turn the adjust-ction b.el.

h 2. Adjusting nut


8-46

EBU12590

Adjusting the rear brake light switchThe rear brake light switch, which is activatedby the brake pedal and rear brake lever, isproperly adjusted when the brake light comeson just before braking takes effect. If neces-sary, adjust the brake light switch as follows.1. Remove panel B. (See page 8-9 for pan-

el removal and installation procedures.)

2. Turn the adjurear brake ligthe brake lighadjusting nut brake light coing nut in dire

3. Install the pan

1. Rear brake light switc

EBU00356 EBU12600

ake levers and brake

ng parts.

e pedal pivot, remove pan- for panel removal and in-s.)

bricant: ased grease ease)


8-47

Cable inspection and lubrication

Lubricate the inner cables and the cable ends.If the cables do not operate smoothly, ask aYamaha dealer to replace them.

Lubricating the brpedalLubricate the pivoti

NOTE:_

To access the brakel B. (See page 8-9stallation procedure_

WARNING

POTENTIAL HAZARDDamaged control cables.WHAT CAN HAPPENCorrosion can result when the outercovering of control cables becomesdamaged. Cables can also becomefrayed or kinked. Operation of controlscould be restricted, which could causean accident or injury.HOW TO AVOID THE HAZARDInspect cables frequently. Replace dam-aged cables.

Recommended lubricant:Yamaha chain and cable lube or SAE 10W30 motor oil

Recommended luLithium-soap-b(all-purpose gr

er and lower pivot

kle upper and lower pivots

2. Lower knuckle

lubricant: based grease


8-48

EBU13110

Rear knuckle upplubrication Lubricate the knucwith a grease gun.

1. Upper knuckle

Recommended Lithium-soap-

EBU01112 EBU11211

el and the nuts.

k on the tire must pointting direction of the wheel. are used for both the frontls. Install the nut with its ta-ards the wheel.


8-49

Wheel removal1. Loosen the wheel nuts.2. Elevate the ATV and place a suitable

stand under the frame.3. Remove the nuts from the wheel.4. Remove the wheel.

1. Nut (× 4)

Wheel installation1. Install the whe

NOTE:_

� The arrow martoward the rota

� Tapered nuts and rear wheepered side tow

_

1. Arrow mark

quipped with a sealed-type it is not necessary to checkdd distilled water in the bat-seems to have discharged, dealer.

inal 2. Positive battery terminal


8-50

2. Lower the ATV so that the wheel is on theground.

1. Tapered nut

3. Tighten the wheel nuts to the specifiedtorque.

EBU00380

BatteryThis machine is ebattery. Thereforethe electrolyte or atery. If the battery consult a Yamaha

1. Negative battery termWheel nut torque:Front: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf)

THE HAZARDith skin, eyes or cloth-ld eyes when working

eep out of reach of chil-

h with water. large quantities of wa-w with milk of magne- or vegetable oil. Getattention.h water for 15 minutes

edical attention. Keepom sparks, flames, cig-ources of ignition. Ven-ing or using in a closed


8-51

CAUTION:Do not try to remove the sealing caps ofthe battery cells. You may damage the bat-tery.

WARNING

POTENTIAL HAZARDFailure to handle batteries or batteryelectrolyte carefully.WHAT CAN HAPPENYou could be poisoned. You could beseverely burned by the sulfuric acid inbattery electrolyte. Batteries produceexplosive gases.

HOW TO AVOID Avoid contact wing. Always shienear batteries. Kdren.Antidote:EXTERNAL: FlusINTERNAL: Drinkter or milk. Follosia, beaten eggprompt medical EYES: Flush witand get prompt mbatteries away frarettes or other stilate when chargspace.

t and the fuse box are locat-

seat.wn, turn off the main switchh of the circuit in question. new fuse of the specified

urn on the main switch. Ifediately blows again, con- dealer.


8-52

EBU00385

Battery maintenance1. When the machine is not used for a

month or longer, remove the battery andstore it in a cool, dark place. Completelyrecharge the battery before reinstallation.

CAUTION:A special battery charger (constant volt-age/ampere or constant voltage) is re-quired for recharging a sealed-typebattery. Using a conventional batterycharger may shorten the battery life.

2. Always make sure the connections arecorrect when putting the battery back inthe machine.

EBU08762*

Fuse replacemen1. The main fuse

ed under the 2. If a fuse is blo

and the switcThen, install aamperage. Tthe fuse immsult a Yamaha

2. Ignition fuse4. Four-wheel drive fuse

eter and clock)

30.0 A 15.0 A 10.0 A

ck fuse: 10.0 A e fuse: 3.0 A m fuse: 10.0 A

10.0 A


8-53

1. Main fuse 2. Fuse box

1. Main fuse 2. Spare main fuse

1. Headlight fuse3. Auxiliary DC jack fuse5. Signaling system fuse6. Backup fuse (for odom7. Spare fuse (× 3)

Specified fuses: Main fuse:Headlight fuse:Ignition fuse:Auxiliary DC jaFour-wheel drivSignaling systeBackup fuse:

light bulb burns out, replace it as fol-

ulb holder cover at the rearht by pulling it off.

cover


8-54

CAUTION:_

To prevent accidental short-circuiting,turn off the main switch when checking orreplacing a fuse. _

EBU14560

Replacing a headIf a headlight bulblows.1. Remove the b

of the headlig

1. Headlight bulb holder

WARNING

POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage tothe electrical system which could leadto a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rat-ing. Never use a material in place of theproper fuse.

ab (× 2)


8-55

2. Remove the headlight bulb holder byturning it counterclockwise.

1. Headlight bulb holder

3. Remove the defective bulb by unhookingthe headlight bulb holder tabs.

1. Headlight bulb holder t

s part of the bulb.

glass part of the head- it free from oil, otherwise of the glass, the luminos-d the bulb life will be ad-Thoroughly clean off anynts on the headlight bulboistened with alcohol or


8-56

4. Insert a new headlight bulb into the bulbholder, and then secure the bulb byhooking the tabs onto the bulb.

1. Do not touch the glas

CAUTION:_

Do not touch thelight bulb to keepthe transparencyity of the bulb, anversely affected. dirt and fingerpriusing a cloth mthinner. _

WARNING

POTENTIAL HAZARD A headlight bulb is hot when it is on andimmediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could startif the bulb touches something flamma-ble. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touchingor removing it.

EBU01089

djustment

have a Yamaha dealerent.

turn the adjusting screw in

turn the adjusting screw in

ing screw


8-57

5. Install the headlight bulb holder by turn-ing it clockwise.

6. Install the headlight bulb holder cover atthe rear of the headlight.

Headlight beam a

CAUTION:_

It is advisable tomake this adjustm_

To raise the beam,direction a.To lower the beam,direction b.

1. Headlight beam adjust

2. Tail/brake light bulb holder

efective bulb from the bulbhing it inward and turning itise.


8-58

EBU09640

Tail/brake light bulb replacement1. Remove the nuts together with the wash-

ers.

1. Tail/brake light unit 2. Nut (× 2)

2. Remove the bulb holder (together withthe bulb) by turning it counterclockwise.

1. Tail/brake light unit

3. Remove the dholder by puscounterclockw

EBU00412

achines receive a rigid in-ipment from the factory,uring operation. Any prob-pression, or ignition sys-oor starting and loss of

shooting chart describes aure for making checks. Ifires any repair, take it to a

ians at a Yamaha dealer-s, experience, and know-rvice your machine. Useha parts on your machine. look like Yamaha parts,ferior. Consequently, theyice life and can lead to ex-


8-59

1. Tail/brake light bulb holder 2. Bulb

4. Install a new bulb in the bulb holder bypushing it inward and turning it clockwise.

5. Install the bulb holder (together with thebulb) by turning it clockwise.

6. Install the washers, and then install thenuts.

TroubleshootingAlthough Yamaha mspection before shtrouble may occur dlem in the fuel, comtems can cause ppower. The troublequick, easy procedyour machine requYamaha dealer.The skilled technicship have the toolhow to properly seonly genuine YamaImitation parts maybut they are often inhave a shorter servpensive repair bills.


8-60

WARNING

POTENTIAL HAZARDChecking the fuel system while smok-ing or near an open flame.WHAT CAN HAPPENFuel can ignite or explode, causing se-vere injury or property damage.HOW TO AVOID THE HAZARDDo not smoke when checking the fuelsystem. Make sure there are no openflames or sparks in the area, includingpilot lights from water heaters or furnac-es.

EBU08061

No fuel. Fuel cock isclogged.

Clean the fuel cock.

k is good.Ignition system isnormal.

k is weak.

Adjust the spark plug gapor replace the spark plug.

park.

Yamaha dealer tot.

ock


8-61

Troubleshooting chartsStarting problems or poor engine performance

1. Fuel

Check if there is fuelin the fuel tank.

There is fuel. Turn the fuel cocklever to “OFF”.

Some fuel. Turn the fuel cocklever to “RES”.

Restart the engine.

No fuel. Supply fuel.

2. Compression

Use the electricstarter to see if there is compression.

There is compression. Compression normal.

No compression. Ask a Yamaha dealer toinspect.

3. Ignition

Remove the spark plug and check the electrodes.

Wet Wipe clean with dry cloth.

DryAttach spark plug cap andground to chassis.

Use theelectric starter.

Spar

Spar

No s

Ask a inspec

4. Battery

Use the electric starter.

Engine turns overquickly. Battery is good.

Engine turns overslowly.

Check the battery lead connections,and charge the battery if necessary.

Check the fuel flow.

Turn the fuel clever to “ON”.

Remove the fuel hosefrom the fuel cock.

porarily used, provided that

THE HAZARD gine to cool before re-ator cap. ick rag over the cap. Al-ing pressure to escapely removing the cap.

ge.

age.Ask a Yamaha dealer to inspect and repair the cooling system.

Add coolant. (See NOTE.)

e. If the engine overheats again, ask a o inspect and/or repair the cooling system.


8-62

Engine overheating

NOTE:_

If it is difficult to get the recommended coolant, tap water can be temit is changed to the recommended coolant as soon as possible. _

WARNING

POTENTIAL HAZARD Removing the radiator cap when the en-gine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid andsteam blown out under pressure.

HOW TO AVOIDWait for the enmoving the radiAlways use a thlow any remainbefore complete

Wait until the engine has cooled.

Check the coolant level in the coolant reservoir and/or radiator.

Level is OK.

Level is low, check the cooling system for leakage.

No leaka

Leak

Restart the enginYamaha dealer t

EBU00419

ressure may cause wa- deterioration of wheel transmission seals and. Many expensive repaired from improper highnt applications such as coin-operated car wash-

ority of the dirt has beensh all surfaces with warm, detergent-type soap. An

or bottle brush is handy forplaces.hine off immediately with

nd dry all surfaces with an towel or soft absorbent


9-1

1-CLEANING AND STORAGE

A. CLEANINGFrequent, thorough cleaning of your machinewill not only enhance its appearance but willimprove its general performance and extendthe useful life of many components.1. Before cleaning the machine:a. Block off the end of the exhaust pipe to

prevent water entry. A plastic bag andstrong rubber band may be used.

b. Make sure the spark plug and all fillercaps are properly installed.

2. If the engine case is excessively greasy,apply degreaser with a paint brush. Donot apply degreaser to the wheel axles.

3. Rinse the dirt and degreaser off with agarden hose. Use only enough pressureto do the job.

CAUTION:Excessive water pter seepage andbearings, brakes,electrical devicesbills have resultpressure detergethose available iners.

4. Once the majhosed off, wawater and mildold toothbrushhard-to-get-at

5. Rinse the macclean water achamois, cleacloth.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

WARNING

ZARDwet brakes after wash-

PEN have reduced stoppingg the chance of an acci-

THE HAZARDafter washing. Apply thetimes at slow speeds tout the linings.


9-2

6. Clean the seat with a vinyl upholsterycleaner to keep the cover pliable andglossy.

7. Automotive type wax may be applied toall painted and chrome plated surfaces.Avoid combination cleaner-waxes. Manycontain abrasives which may mar thepaint or protective finish. When finished,start the engine and let it idle for severalminutes.

POTENTIAL HAOperation with ing.WHAT CAN HAPWet brakes mayability, increasindent.HOW TO AVOIDTest the brakes brakes several let friction dry o

EBU00530

park plug, pour about one SAE 10W30 or 20W40 spark plug hole and rein- plug. Ground the spark

turn the engine over seve-t the cylinder wall with oil.ntrol cables.ame to raise all wheels off

ag over the exhaust pipent moisture from entering. humid or salt-air atmo-ll exposed metal surfaces of oil. Do not apply oil tots or the seat cover.


9-3

B. STORAGELong term storage (60 days or more) of yourmachine will require some preventive proce-dures to guard against deterioration. Afterthoroughly cleaning the machine, prepare forstorage as follows:1. Fill the fuel tank with fresh fuel and add

the specified amount of Yamaha FuelStabilizer and Conditioner or an equiva-lent product.

NOTE:Use of fuel stabilizer and conditioner elimi-nates the need to drain the fuel system. Con-sult a Yamaha dealer if the fuel system needsto be drained instead.

2. Remove the stablespoon ofmotor oil in thestall the sparkplug wire and ral times to coa

3. Lubricate all co4. Block up the fr

the ground.5. Tie a plastic b

outlet to preve6. If storing in a

sphere, coat awith a light filmany rubber par

Specified amount:1 oz of stabilizer to each gallon of fuel (or 7.5 cc of stabilizer to each liter of fuel)


9-4

7. Remove the battery and charge it. Storeit in a dry place and recharge it once amonth. Do not store the battery in an ex-cessively warm or cold place (less than0 °C (30 °F) or more than 30 °C (90 °F)).

NOTE:Make any necessary repairs before storingthe machine.

EBU00428

FM450FA

SOHC

cylinder

2.95 in)

er


10-1

1-SPECIFICATIONS

Model Y

Dimensions:Overall length 1,993 mm (78.5 in)

Overall width 1,093 mm (43.0 in)

Overall height 1,120 mm (44.1 in)Seat height 830 mm (32.7 in)

Wheelbase 1,233 mm (48.5 in)

Ground clearance 245 mm (9.65 in)Minimum turning radius 3,000 mm (118.1 in)

Basic weight:

With oil and full fuel tank 285.0 kg (628 lb)Engine:

Engine type Liquid-cooled 4-stroke,

Cylinder arrangement Forward-inclined singleDisplacement 421.0 cm3

Bore × stroke 84.5 × 75.0 mm (3.33 ×Compression ratio 10.00 : 1Starting system Electric and recoil start

Lubrication system Wet sump

1

2

3

4

5

6

7

8

9

10

11

12

13

14

G type or higher

.43 US qt)

.54 US qt)

FM450FA

50˚ 70˚ 90˚ 110˚ 130˚F

(10W30) or SAE 10W30

10˚ 20˚ 30˚ 40˚ 50˚C

ALUBE 4 (20W40) or SAE 20W40

lutch slippage (since the en-s the clutch), do not mix anyo not use oils with a diesel or oils of a higher qualityition, do not use oils labeledNG II” or higher.


10-2

Engine oil:Type

Recommended engine oil classification API Service SE, SF, S

Quantity:

Without oil filter cartridge replacement 2.30 L (2.02 Imp qt, 2With oil filter cartridge replacement 2.40 L (2.11 Imp qt, 2

Model Y

0˚ 10˚ 30˚

YAMALUBE 4

SAE 5W30

-20˚ -10˚ 0˚

YAM

CAUTION:In order to prevent cgine oil also lubricatechemical additives. Dspecification of “CD”than specified. In add“ENERGY CONSERVI

id gear oil4 US qt)

id gear oil4 US qt)

7 US qt)

E ONLY

.96 US gal)9 US gal)

FM450FA


10-3

Final gear case oil:

Type SAE 80 API GL-4 HypoQuantity 0.23 L (0.20 Imp qt, 0.2

Differential gear case oil:

Type SAE 80 API GL-4 HypoQuantity 0.23 L (0.20 Imp qt, 0.2

Radiator capacity (including all routes): 1.30 L (1.14 Imp qt, 1.3

Air filter: Wet type elementFuel:

Type UNLEADED GASOLIN

Fuel tank capacity 15.0 L (3.30 lmp gal, 3Fuel reserve amount 4.5 L (0.99 lmp gal, 1.1

Carburetor:

Type/quantity BSR33 / 1Manufacturer MIKUNI

Model Y

.028 in)

atic

7.944)

FM450FA


10-4

Spark plug:

Type/manufacturer DR8EA / NGKSpark plug gap 0.6–0.7 mm (0.024–0

Clutch type: Wet, centrifugal autom

Transmission:Primary reduction system V-belt

Secondary reduction system Shaft drive

Secondary reduction ratio 39/24 × 24/18 × 33/9 (Transmission type V-belt automatic

Operation Left hand operation

Reverse gear 29/17 (1.706)Sub transmission ratio low 45/16 (2.813)

high 38/23 (1.652)

Chassis:Frame type Steel tube frame

Caster angle 2.5°

Trail 8.5 mm (0.33 in)Tire:

Type Tubeless

Size front AT25 × 8 - 12rear AT25 × 10 - 12

Model Y

t operation

r

r

FM450FA


10-5

Brake:

Front brake type Dual disc brakeoperation Right hand operation

Rear brake type Single disc brake

operation Left hand and right fooSuspension:

Front suspension Double wishbone

Rear suspension Double wishboneShock absorber:

Front shock absorber Coil spring / oil dampe

Rear shock absorber Coil spring / oil dampeWheel travel:

Front wheel travel 160.0 mm (6.30 in)

Rear wheel travel 180.0 mm (7.09 in)Electrical:

Ignition system DC. C.D.I.

Generator system A.C. magnetoBattery type YTX20L-BS

Battery capacity 12 V 18.0 Ah

Headlight type: Krypton bulb

Model Y

FM450FA


10-6

Bulb voltage, wattage × quantity:

Headlight 12 V 30W/30.0 W × 2Tail/brake light 12 V 5W/21.0 W × 1

Indicator light:

Neutral indicator light LEDReverse indicator light LED

Coolant temperature warning light LED

Park indicator light LEDHigh-range indicator light LED

Low-range indicator light LED

Differential gear lock indicator light LEDFuses:

Main fuse 30.0 A

Headlight fuse 15.0 A Ignition fuse 10.0 A

Auxiliary DC jack fuse 10.0 A

Four-wheel drive fuse 3.0 ASignaling system fuse 10.0 A

Backup fuse 10.0 A

Model Y

11-1

EBU00430

1-NOISE REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop-erative by any person other than for purposes of maintenance, repair, or replacement of any de-vice or element of design incorporated into any new vehicle for the purpose of noise control priorto its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle aftersuch device or element of design has been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTEDBELOW.”These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system

MufflerExhaust pipe Silencer

Intake systemAir cleaner caseAir cleaner elementIntake duct


12-1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

EBU13653

1-MAINTENANCE RECORD

Copies of work orders and/or receipts for parts you purchase and install will be required to docu-ment maintenance done in accordance with the warranty. The chart below is printed only as a re-minder to you that the maintenance work is required. It is not acceptable proof of maintenancework.ACL-06E

MAINTENANCE INTERVAL DATE OF

SERVICEMILEAGE

SERVICING DEALER NAME AND ADDRESS

REMARKSmonth km (mi) hours

1 320 (200) 20

3 1,200 (750) 75

6 2,400 (1,500) 150

12 4,800 (3,000) 300

18 7,200 (4,500) 450

24 9,600 (6,000) 600

30 12,000 (7,500) 750

36 14,400 (9,000) 900

42 16,800 (10,500) 1,050

48 19,200 (12,000) 1,200

54 21,600 (13,500) 1,350

60 24,000 (15,000) 1,500


EBU00432


13-1

YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY

1

2

3

4

5

6

7

8

9

10

11

12

13

14


13-2

EBU00435


14-1

YAMAHA EXTENDED SERVICE (Y.E.S.)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

ntial hazard that couldinjury or death.


14-2

EBU00436

WARNING_

Indicates a poteresult in serious


EBU00437

1D9-F8199-10LIT-11626-18-35

READ THIS MANUAL CAREFULLY!It contains important safety information.

This ATV should not be ridden by anyone under 16 years of age.WARNING

YFM450FAT

OWNER’S MANUAL

PRINTED IN USA2004.06-4.4×1 CR

(E)

YAMAHA MOTOR CO., LTD.

EBU00438

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-pavement may seriously affect handling and control.

Improper ATV use can result in SEVERE INJURY or DEATH.

NEVER operate: without proper training or instruction. at speeds too fast for your skills or the conditions. on public roads-a collision can occur with another vehicle. with a passenger-passengers affect balance and steering and increase risk of losing control.

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

B EE R

B EE R

yamaha kodiak 450 lit-11626-18-35_972

Documents

atv rider

new atv

improper atv use

important information

important safety information

maintenance ofyour atv

replacement manual

important safety message