Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM45FGZ YFM45FGHZ YFM450FAZ 37S-F8199-61...
Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2009.06-0.3×1 CR (E,F,S)
Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45FGZ YFM45FGHZ YFM450FAZ 37S-F8199-61-E0...
Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 98/37/EC, 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM450FWAN (YFM45FG) (5Y4AJ14W090515692–) (YFM45FGH) (5Y4AJ16W090501601–)
Page 5 Congratulations on your purchase of the Yamaha YFM45FGZ/YFM45FGHZ/YFM450FAZ. This ATV rep- resents the result of many years of Yamaha experience in the production of fine sporting, touring, and pac- esetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
Page 6: Important Manual Information
EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
Page 7: Important Notice
Please check your local riding laws and regulations before operating this ATV. EBU17410 YFM45FGZ/YFM45FGHZ/YFM450FAZ OWNER’S MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st edition, May 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
Page 8: Table Of Contents
EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel ............4-14 SPECIFICATION LABELS ......1-1 Fuel cock ..........4-16 Starter (choke) ..........4-17 SAFETY INFORMATION ......2-1 Seat ............4-18 Storage compartments ......4-19 DESCRIPTION ..........3-1 Front carrier ..........4-21 Left view ............3-1 Rear carrier ..........4-21 Right view............
Page 9 OPERATION ..........6-1 PERIODIC MAINTENANCE AND Starting a cold engine ........ 6-1 ADJUSTMENT..........8-1 Starting a warm engine ......6-3 Owner’s manual and tool kit .......8-1 Operating the drive select lever and Periodic maintenance chart for the driving in reverse ........6-3 emission control system ......8-3 Engine break-in ..........
Page 10 Changing the brake fluid ......8-41 Troubleshooting charts ......8-62 Checking the front brake lever free play ............8-41 CLEANING AND STORAGE ......9-1 Adjusting the brake pedal and rear brake Cleaning ............9-1 lever free play and checking the brake Storage ............9-2 pedal position .........
Page 11: Location Of The Warning And Specification Labels
Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. For Europe 9 10...
Page 12 < 40 kg ( 88 lbs) 37S-F817R-00 1P0-F816P-20 < 80 kg ( 176 lbs) 37S-F817R-10 25.0 kPa 25.0 kPa 0.25 kgf/cm² 0.25 kgf/cm² < 5880 N 3.6 psi 3.6 psi < 600 kgf < 1322 lbf 5FU-F816M-M0 < 147 N <...
Page 13 1P0-F816L-20 1P0-F816R-00...
Page 14 < 0.5 kg ( 1 lb ) 37S-F816N-00 37S-F816S-00 YEAR OF CONSTRUCTION : 2009 MODEL : YFM450FWAN YAMAHA MOTOR CO., LTD. MAX.POWER : 19.4 kW 2500 SHINGAI, IWATA, JAPAN MASS IN RUNNING ORDER : 285 kg 37S-F155A-10...
Page 15 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
Page 16 NEVER use with drugs or alcohol. Adjust tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids. Turning 4WD-LOCK (“DIFF.LOCK”) takes more effort.
Page 17 This pictogram shows trailer Hitch Tow weight limit. (Combined weight of the trailer and all cargo in the trailer.) Overloading can cause loss of control. Loss of control can result in severe injury or death. This pictogram shows trailer Hitch Tongue weight limit.
Page 18 For Oceania...
Page 19 25 kPa, (3.6 psi) 25 kPa, (3.6 psi) 22 kPa, (3.2 psi) 22 kPa, (3.2 psi) ( 6 0 0 k g f ) 5880 N 1322 5FU-F816M-20 ( 1 5 k g f ) 37S-F151K-00...
Page 20 UNDER 1P0-F816L-00 1-10...
Page 21 WARNING Fuel vapors can be a fire or explosion hazard. To avoid injury or death, never store fuel or flammable liquids in this storage compartment. Storage should not exceed 0.5 kg (1 lb) 37S-F151F-00 1-11...
Page 22: Safety Information
EBU17431 SAFETY INFORMATION EBU17503 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
Page 23 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
Page 24 steady speed when climbing a hill. If you stall or Always be sure there are no obstacles or people roll backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
Page 25 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT.
Page 26: Description
EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 1. Rear shock absorber assembly spring preload adjusting ring 2. Fuel cock 2. Spark arrester 3. Recoil starter 3. Rear storage compartment and tool kit 4. Throttle stop screw 4.
Page 27: Controls And Instruments
EBU17712 Controls and instruments The ATV you have purchased may differ slightly 6 7 8 from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Horn switch 5. Drive select lever 6. Multi-function display 7.
Page 28: Instrument And Control Functions
EBU17733 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.
Page 29: Indicator Lights And Warning Light
10 seconds or more. If the indicator light flashes under any other circum- stances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. EBU17860 Neutral indicator light “...
Page 30 Start the engine after making sure that the the indicator light continue to flash, the differen- warning light is out. Continuous use while tial is not locked. In this case, start moving to al- the warning light is on may cause damage to low time for the differential to lock.
Page 31: Multi-Function Display
EBU18036 an hour meter (which shows the total time the Multi-function display engine has been running) Odometer and tripmeter modes Pushing the “TRIP/ODO” button switches the dis- play between the odometer mode “ODO” and the tripmeter modes “TRIP A” and “TRIP B” in the fol- lowing order: ODO →...
Page 32: Fuel Gauge
To set the clock 1. Set the display to the clock mode. If the ATV runs out of fuel, move the fuel cock lever 2. Push the “ / ” button until the clock starts to the “RES” position. Approximately 4.5 L (1.19 flashing.
Page 33 EBU18080 If this should happen, remove the battery and Engine stop switch “ ” recharge it. See page 8-51 for battery charging Set this switch to “ ” before starting the engine. information. The engine stop switch controls the ignition and stops the engine when it is running.
Page 34 In circumstances. Changing from two-wheel this case, take the ATV to a Yamaha dealer at the drive to four-wheel drive or vice versa while first opportunity.
Page 35 handle differently. This could distract the oper- ator and increase the risk of losing control and of causing an accident. This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice versa. Select the appropriate drive according to the ter- rain and the conditions.
Page 36 pectedly. This could distract the operator and “LOCK” (four-wheel drive with the differential increase the risk of losing control and causing gear locked): Power is supplied to the rear and an accident. front wheels and the differential gear is locked. Unlike in four-wheel drive, all wheels turn at the EWB00140 same speed.
Page 37 1. Differential gear lock lever 1. On-Command differential gear lock switch “4WD”/“LOCK” 2. On-Command four-wheel-drive switch “2WD”/“4WD” To release the differential gear lock, stop the ATV Stop the ATV, move the differential gear lock lever and push the switch to the “4WD” position. to position (a), and then push the differential gear lock switch in to the “LOCK”...
Page 38: Throttle Lever
Riding before the differential gear lock is proper- ly engaged (e.g., when the indicator and indica- tor light are flashing) will cause the vehicle speed to be limited until engagement is com- plete. When the ATV is in four-wheel-drive differential gear lock, the maximum traveling speed is limit- ed to 35 km/h (22 mi/h).
Page 39: Front Brake Lever
crease the maximum engine power available 3. Tighten the locknut. and the maximum speed of the ATV, turn the EBU18391 adjusting screw in direction (b). Do not turn Front brake lever the adjusting screw out more than 12 mm The front brake lever is located on the right handle- (0.47 in) or the throttle cable could be dam- bar.
Page 40: Drive Select Lever
EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. 1.
Page 41: Fuel Tank Cap
1. Recoil starter 1. Fuel tank cap EWB00330 EBU18754 WARNING Fuel Always shift the drive select lever to park posi- Make sure there is sufficient gasoline in the tank. tion before starting the engine, otherwise the EWB02521 ATV could start to move unexpectedly, which WARNING could cause an accident.
Page 42 of sparks, open flames, or other sources of ig- Recommended fuel: nition such as the pilot lights of water heaters UNLEADED GASOLINE ONLY and clothes dryers. For Europe: Regular unleaded gasoline only 2. Do not overfill the fuel tank. When refueling, with a research octane number of 91 or high- be sure to insert the pump nozzle into the fuel tank filler hole.
Page 43: Fuel Cock
Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane 1. Arrow mark pointing to “OFF”...
Page 44: Starter (Choke)
1. Arrow mark pointing to “ON” 1. Arrow mark pointing to “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.
Page 45: Seat
Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Seat 2. Seat lock lever To install the seat Insert the projections on the front of the seat into 1.
Page 46: Storage Compartments
The front storage compartment is located at the front right side of the ATV. To access the storage compartment, remove the storage compartment cover by turning it counterclockwise. 1. Projection 2. Seat holder EBU29252 Storage compartments 1. Front storage compartment cover This ATV is equipped with two storage compart- ments.
Page 47 When storing any documents in the storage com- partments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartments. Do not exceed the load limit of 0.5 kg (1 lb) for the front storage compartment or 2.0 kg (4 lb) for the rear storage compartment.
Page 48: Front Carrier
EBU18962 Front carrier Do not exceed the load limit of 40.0 kg (88 lb) for the front carrier. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. EBU18972 Rear carrier Do not exceed the load limit of 80.0 kg (176 lb) for the rear carrier.
Page 49 1. Special wrench Spring preload setting: Minimum (soft): Standard: 1. Spring preload adjusting ring 2. Position indicator Maximum (hard): A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-22...
Page 50: Auxiliary Dc Jack
EBU19182 Maximum rated capacity for the auxiliary DC Auxiliary DC jack jack: The auxiliary DC jack is located at the front right DC 12 V, 10 A (120 W) side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc.
Page 51: Pre-Operation Checks
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
Page 52 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-39, 8-40, 8-41 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.
Page 53: Fuel
EBU19590 Check that there is no free play in the front brake Final gear oil lever. If there is free play, have a Yamaha dealer Make sure that the final gear oil is at the specified check the brake system.
Page 54: Throttle Lever
If there is any leakage, the brake proper tire pressure may cause severe injury system should be checked by a Yamaha dealer. or death from loss of control or rollover. Tire pressure below the minimum specified could...
Page 55 Recommended tire pressure: Front 25.0 kPa (0.250 kgf/cm², 3.6 psi) Rear 25.0 kPa (0.250 kgf/cm², 3.6 psi) Minimum tire pressure: Front 22.0 kPa (0.220 kgf/cm², 3.2 psi) Rear 22.0 kPa (0.220 kgf/cm², 3.2 psi) Maximum tire seating pressure: 1. Low-pressure tire gauge Front 250 kPa (2.5 kgf/cm², 36 psi) Tire wear limit...
Page 56 The tires and rims that came with your ATV were After extensive tests, only the tires listed below designed to match the performance capabilities have been approved for this model by Yamaha and to provide the best combination of handling, Motor Manufacturing Corporation of America.
Page 57: Chassis Fasteners
EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.
Page 58: Operation
Read the Owner’s Manual carefully before riding light should come on. If the indicator light does the ATV. If there is a control or function you do not not come on, have a Yamaha dealer check understand, ask your Yamaha dealer. the electrical circuit.
Page 59 Position (3): Cold engine start with ambient temperature If the engine fails to start, release the start above 25 °C (80 °F). switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery ener- gy.
Page 60: Starting A Warm Engine
EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. EBU20441 Operating the drive select lever and driving in reverse ECB00170...
Page 61 6. P (Park) When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the elec- trical circuit. Due to the synchronizing mechanism in the en- gine, the indicator light may not come on until the...
Page 62: Engine Break-In
There is never a more important period in the life of engine break-in period, immediately have a your engine than the first 320 km (200 mi) or 20 Yamaha dealer check the ATV. hours of riding. For this reason, you should read the following material carefully.
Page 63: Parking On A Slope
ATV. Many companies with no con- nection to Yamaha manufacture parts and acces- sories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies pro- duce. Therefore, Yamaha can neither endorse nor...
Page 64 Yamaha or modifications not specifically recom- bulky object attached to the handlebars which mended by Yamaha, even if sold and installed by could make steering difficult, an accessory that a Yamaha dealer. limits your ability to move around on the seat, or one that limits your view.
Page 65 Never exceed the weight limits shown. An over- just the load in the trailer, if necessary, to reduce loaded ATV can be unstable. the weight on the hitch. If you are carrying cargo and towing a trailer, include the tongue weight in MAXIMUM LOADING LIMIT the maximum ATV load limit.
Page 66: Riding Your Atv
EBU21141 RIDING YOUR ATV...
Page 67: Getting To Know Your Atv
EBU29234 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding Do not operate this ATV or allow anyone else instructions for recreational riding.
Page 68 Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
Page 69 Apparel Always wear the following to reduce risk of injury in an accident: Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
Page 70 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
Page 71 opening, even when the throttle lever is pushed to Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see box in this section or ve- the maximum engine power available and de- hicle labeling).
Page 72 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of cargo, rider, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 210.0 kg (463 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
Page 73 ATV should be during operation or after leaving the ATV, do not let genuine Yamaha or equivalent components de- brush, grass and other materials collect under the signed for use on this ATV and should be installed vehicle, near the muffler or exhaust pipe, or next to and used according to instructions.
Page 74: Be Careful Where You Ride
To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
Page 75 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do not ways be alert to changing terrain conditions ride on any paved public street, road or motorway. when operating the ATV.
Page 76 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.
Page 77: Turning Your Atv
Select a large, flat, unpaved area to become famil- ECB00251 NOTICE iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice Do not shift from low-range to high-range or control of the throttle, brakes, shifting procedures, vice versa without coming to a complete stop.
Page 78: Climbing Uphill
As you approach a curve, slow down and begin to may continue to go straight. If the ATV doesn’t turn the handlebars in the desired direction. As you turn, come to a stop and then practice the proce- do so, put your weight on the footboard to the out- dure again.
Page 79 Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
Page 80 Do not attempt to climb hills until you have mas- If you are climbing a hill and you find that you have tered basic maneuvers on flat ground. Always not properly judged your ability to make it to the check the terrain carefully before attempting any top, you should turn the ATV around while you still hill.
Page 81: Riding Downhill
remount, following the procedure described in the Always check the terrain carefully before Owner’s Manual. WARNING! Stalling, rolling you start down any hill. backwards or improperly dismounting while Never operate the ATV on hills too steep for climbing a hill could result in ATV overturning. the ATV or for your abilities.
Page 82: Crossing A Slope
Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this ATV is in “4WD”, all wheels (front and rear) are interconnected by the drive train.
Page 83: Crossing Through Shallow Water
Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill.
Page 84 The ATV can be used to cross slow moving, shal- ability. WARNING! Wet brakes may have re- low water of up to a maximum of 35 cm (14 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.
Page 85 Wash the ATV in fresh water if it has been operat- ed in salt water or muddy conditions. 1. Drive select lever box check hose 1. Air filter case check hose 1. Storage compartment check hose 1. V-belt cooling duct check hose (left front side of ATV) 7-20...
Page 86: Riding Over Rough Terrain
RIDING OVER ROUGH TERRAIN EWB01651 WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.
Page 87 Learn to safely control skidding or sliding by If the rear wheels of your ATV start to slide side- practicing at low speeds and on level, ways, control can usually be regained (if there is smooth terrain. room to do so) by steering in the direction of the On extremely slippery surfaces, such as ice, slide.
Page 88: What To Do If
WHAT TO DO IF... THE REAR BRAKE IF THE ATV IS IN “2WD” – This section is designed to be a reference guide the ATV may tip over on top of you. Dismount only. Be sure to read each section on riding tech- the ATV on the uphill side.
Page 89: Periodic Maintenance And Adjustment
If you are not fa- EBU21731 miliar with vehicle service, have a Yamaha Owner’s manual and tool kit dealer perform the service. Be sure to put this owner’s manual in the plastic...
Page 90 However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.
Page 91: Periodic Maintenance Chart For The Emission Control System
However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 92 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.
Page 93: General Maintenance And Lubrication Chart
However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 94 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years •...
Page 95 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ 16 * Engine mount necessary. •...
Page 96 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. Throttle lever hous- • Check throttle cable free play and adjust if neces- √...
Page 97: Removing And Installing Panels
EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel C 2.
Page 98 To install one of the panels 1. Place the panel in its original position. 8-10...
Page 99 Panel B To remove the panel Remove the bolt, and then take the panel off. 1. Panel B 2. Bolt To install the panel Place the panel in the original position and install the bolt. NOTICE: When installing the panel, be sure not to pinch the cables or wires.
Page 100 1. Carrier bolt (top) 1. Carrier bolt (under the fenders) 2. Remove the carrier bolts under the fenders, 3. Remove the quick fastener screws, and then and then take the carrier off. pull the panel upward to remove it. 8-12...
Page 101 Tightening torques: Carrier bolt (top): 34 Nm (3.4 m·kgf, 24 ft·lbf) Carrier bolt (under fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Panel E To remove the panel Remove the bolts, and then take the panel off. 1. Quick fastener screw 2.
Page 102: Checking The Spark Plug
To install the panel Place the panel in the original position and install the bolts. Panel F To remove the panel Pull outward on the areas shown. EBU23223 Checking the spark plug The spark plug is an important engine component, which is easy to check.
Page 103 (the ideal color when the ATV is ridden normally). If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-15...
Page 104 2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.
Page 105: Engine Oil And Oil Filter Cartridge
EBU23328 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals spec- ified in the periodic maintenance and lubrication chart.
Page 106 To change the engine oil (with or without oil fil- ter cartridge replacement) 1. Place the ATV on a level surface. 2. Remove panel F. (See page 8-9.) 3. Start the engine, warm it up for several min- utes, and then turn it off. 4.
Page 107 7. Remove the oil filter cartridge with an oil filter wrench. 1. Oil filter wrench An oil filter wrench is available at a nearby Yamaha dealer. 8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
Page 108 1. O-ring 1. Torque wrench Tightening torque: Oil filter cartridge: Make sure that the O-ring is properly seated. 17 Nm (1.7 m·kgf, 12 ft·lbf) 9. Install the new oil filter cartridge with an oil fil- 10. Install panels E and D. ter wrench, and then tighten it to the specified 11.
Page 109: Final Gear Oil
The final gear case must be checked for oil leak- engine and exhaust system have cooled down. age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- ECB00300 dition, the final gear oil level must be checked and...
Page 110 2. Remove the final gear oil filler bolt, and then To change the final gear oil check the oil level in the final gear case. The 1. Place the ATV on a level surface. oil level should be at the brim of the filler hole. 2.
Page 111 1. Final gear oil drain bolt 1. Final gear oil filler bolt 2. Correct oil level 5. Install the drain bolt, and then tighten it to the 3. Final gear oil specified torque. Recommended final gear oil: Tightening torque: See page 10-1. Final gear oil drain bolt: 24 Nm (2.4 m·kgf, 17 ft·lbf) If the recommended oil is not available, SAE80W-...
Page 112: Differential Gear Oil
The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil level must be 1. Differential gear oil checked and the oil changed as follows at the in- 2.
Page 113 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 4. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf)
Page 114: Coolant
EBU23470 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. EBU27124 To check the coolant level 1. Place the ATV on a level surface. The coolant level must be checked on a cold en- 1.
Page 115 If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. [ECB01011] Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt, 0.22 Imp.qt)
Page 116 pressure. Always place a thick rag over the cap when opening. Allow any remaining pressure to escape before completely removing the cap. 1. Place the ATV on a level surface. 2. Remove panels E and F. (See page 8-9.) 3. Place a container under the engine, and then remove the coolant drain bolt.
Page 117 1. Coolant reservoir hose 1. Radiator cap 9. After draining the coolant, thoroughly flush the 6. Remove panel D. (See page 8-9.) cooling system with clean tap water. 7. Remove the coolant reservoir cap. 10. Replace the coolant drain bolt washer if it is 8.
Page 118: Cleaning The Air Filter Element
Do not use hard water or salt water since they are If any leakage is found, have a Yamaha dealer harmful to the engine. [ECB00991] check the cooling system.
Page 119 1. Air filter case check hose 1. Air filter case cover holder 2. Air filter case cover 1. Place the ATV on a level surface. 4. Pull the air filter element out of the air filter 2. Remove the seat. (See page 4-18.) case.
Page 120 1. Air filter element 1. Air filter element frame 2. Sponge material 5. Pull off the air filter element lock plate, and 3. Air filter element lock plate then remove the sponge material from the air 6. Wash the sponge material gently but thor- filter element frame.
Page 121: Cleaning The Spark Arrester
40 hours. It should be cleaned and lubricated more damaged. often if the ATV is operated in extremely dusty ar- 9. Apply Yamaha foam air filter oil or other qual- eas. Each time the air filter element maintenance ity foam air filter oil to the sponge material.
Page 122 1. Bolt 1. Tailpipe 2. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 4. Insert the tailpipe into the muffler and align the muffler. bolt holes. 3. Tap the tailpipe lightly, and then use a wire 5.
Page 123: V-Belt Cooling Duct Check Hose
Always let the exhaust system cool prior to If water drains from the V-belt case after removing touching exhaust components. the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts. EBU23920 V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it.
Page 124: Adjusting The Carburetor
Therefore, most carburetor adjustments should be left to a The engine is warm when it quickly responds to the Yamaha dealer, who has the necessary profes- throttle. sional knowledge and experience. The adjustment 2. Remove panel D. (See page 8-9.) described in the following section, however, may 3.
Page 125: Adjusting The Throttle Cable Free Play
3. To increase the throttle cable free play, turn If the specified idling speed cannot be obtained as the throttle cable free play adjusting bolt in di- described above, have a Yamaha dealer make the rection (a). To decrease the throttle cable free adjustment.
Page 126: Valve Clearance
The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.
Page 127: Checking The Front Brake Pads And Rear Brake Friction Plates
(See page 8-59.) sure the lining thickness. If a brake pad is dam- aged or if the lining thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the brake EBU28421 Rear brake friction plates pads as a set.
Page 128: Checking The Brake Fluid Level
If the have a Yamaha dealer replace the brake friction brake fluid level is low, be sure to check the brake plates as a set. pads for wear and the brake system for leakage.
Page 129: Changing The Brake Fluid
Yamaha dealer check the cause. EBU24281 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic 1. No brake lever free play maintenance and lubrication chart. In addition,...
Page 130: Adjusting The Brake Pedal And Rear Brake Lever Free Play And Checking The Brake Pedal Position
EBU28637 Adjusting the brake pedal and rear brake lever free play and checking the brake pedal position The brake pedal and brake lever free play and the brake pedal position must be checked and, if nec- essary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
Page 131 1. Locknut 1. Brake lever free play adjusting nut 2. Brake lever free play adjusting bolt 3. Push the brake camshaft lever in direction (a) 2. Fully loosen the brake lever free play adjust- until it stops [apply approximately 50 N (5.0 ing nut on the brake cable at the final gear kgf, 11.2 lbf) of force], and then turn the brake case.
Page 132 1. Brake pedal free play adjusting nut 1. Brake lever free play adjusting nut 2. Brake camshaft lever 2. Brake camshaft lever 3. Gap “A” 3. Gap “B” 4. Push the brake camshaft lever in direction (a) 5. Check the brake lever free play and, if neces- until it stops [apply approximately 50 N (5.0 sary, adjust it by turning the brake lever free kgf, 11.2 lbf) of force], and then turn the brake...
Page 133: Axle Boots
Check the axle boots for tears or Make sure the brake pedal does not move. damage. If any damage is found, have them re- placed by a Yamaha dealer. Checking the brake pedal position The top of the brake pedal should be positioned 75.0–85.0 mm (2.95–3.35 in) above the footboard.
Page 134: Brake Light Switches
The brake light switch for the brake pedal can be adjusted as follows, but the front brake light switch should be adjusted by a Yamaha dealer. 1. Remove panel B. (See page 8-9.) 2. Turn the brake light switch adjusting nut while holding the brake light switch in place.
Page 135: Checking And Lubricating The Cables
If a cable is damaged or does not move pivots should be lubricated if necessary. smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil 8-47...
Page 136: Checking And Lubricating The Brake Pedal
Rear brake lever Recommended lubricants: Front brake lever: Silicone grease Rear brake lever: Lithium-soap-based grease Front brake lever EBU28832 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.
Page 137: Checking The Wheel Hub Bearings
If there is play and lubrication chart. in a wheel hub or if a wheel does not turn smoothly, Lubricate the universal joint using a grease gun. have a Yamaha dealer check the wheel hub bear- ings. Recommended lubricant: Lithium-soap-based grease...
Page 138: Checking The Stabilizer Bushes
Lubricate the pivoting points using a grease gun. EBU25103 Lubricating the steering shaft Recommended lubricant: The steering shaft must be lubricated by a Yamaha Lithium-soap-based grease dealer at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant:...
Page 139: Battery
EBU29184 Batteries produce explosive gases. Keep Battery sparks, flame, cigarettes or other sources of ig- This model is equipped with a VRLA (Valve Regu- nition away. Ventilate when charging or using lated Lead Acid) battery. There is no need to check in an enclosed space.
Page 140 To charge the battery ECB00940 Have a Yamaha dealer charge the battery as soon NOTICE as possible if it seems to have discharged. Keep in Always keep the battery charged. Storing a dis-...
Page 141: Replacing A Fuse
To install the battery EBU25326 Replacing a fuse The main fuse and the fuse box are located under Be sure the battery is fully charged. the seat. (See page 4-18.) 1. Place the battery in its compartment. 2. Connect the positive battery lead first, then connect the negative battery lead by installing their bolt.
Page 142 1. Main fuse 1. Headlight fuse 2. Spare main fuse 2. Ignition fuse 3. Auxiliary DC jack fuse 4. Four-wheel-drive motor fuse 5. Signaling system fuse 6. Backup fuse (for odometer and clock) 7. Spare fuse If a fuse is blown, replace it as follows. 1.
Page 143: Replacing A Headlight Bulb
2. Remove the blown fuse, and then install a 4. If the fuse immediately blows again, have a new fuse of the specified amperage. Yamaha dealer check the electrical system. WARNING! Always use a fuse of the spec- EBU25481 ified rating, and never use a substitute ob- Replacing a headlight bulb ject in place of the proper fuse.
Page 144 4. Remove the burnt-out bulb by pulling it out. 5. Insert a new headlight bulb into the bulb hold- er by pushing it in. NOTICE: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.
Page 145: Adjusting A Headlight Beam
8. Adjust the headlight beam if necessary. EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make 1. Headlight beam adjusting screw this adjustment. EBU25621 To raise a headlight beam, turn the headlight beam Replacing the tail/brake light bulb adjusting screw in direction (a).
Page 146 1. Tail/brake light assembly 1. Tail/brake light assembly 2. Nut 2. Tail/brake light bulb holder 2. Remove the bulb holder (together with the 3. Remove the burnt-out bulb by pushing it in bulb) by turning it counterclockwise. and turning it counterclockwise. 8-58...
Page 147: Removing A Wheel
1. Tail/brake light bulb holder 1. Wheel nut 2. Tail/brake light bulb 3. Elevate the ATV and place a suitable stand 4. Insert a new bulb into the bulb holder, push it under the frame. in, and then turn it clockwise until it stops. 4.
Page 148 Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Tapered nut 3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified torques.
Page 149: Troubleshooting
However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.
Page 150: Troubleshooting Charts
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.
Page 151 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.
Page 152: Cleaning And Storage
EBU25860 CLEANING AND STORAGE EBU25881 tion of wheel bearings, brakes, transmis- Cleaning sion seals and electrical devices. Many Frequent, thorough cleaning of your ATV will not expensive repair bills have resulted from only enhance its appearance but will improve its improper high-pressure detergent applica- general performance and extend the useful life of tions such as those available in coin-oper-...
Page 153: Storage
EBU25933 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inder, piston rings, etc.
Page 154 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.
Page 155: Specifications
EBU25960 SPECIFICATIONS Dimensions: Vibration on handlebar (EN1032, ISO5008): YFM45FGHZ Will not exceed 2.5 m/s² Overall length: YFM45FGZ Will not exceed 2.5 m/s² 1991 mm (78.4 in) Engine: Overall width: 1093 mm (43.0 in) Engine type: Overall height: Liquid cooled 4-stroke, SOHC 1120 mm (44.1 in)
Page 156 Type: YFM450FAZ Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: ACC-SHAFT-LU-00) YFM45FGHZ Yamaha Friction Modified Shaft Drive Gear 50 ˚C YFM45FGZ Yamaha Friction Modified Shaft Drive Gear SAE 5W-30 Quantity: SAE 10W-30 0.50 L (0.53 US qt, 0.44 Imp.qt)
Page 157 Recommended fuel: Low range: YFM450FAZ Unleaded gasoline only 45/16 (2.813) YFM45FGHZ Regular unleaded gasoline only High range: YFM45FGZ Regular unleaded gasoline only 38/23 (1.652) Fuel tank capacity: Chassis: 15.0 L (3.96 US gal, 3.30 Imp.gal) Fuel reserve amount: Frame type: 4.5 L (1.19 US gal, 0.99 Imp.gal)
Page 158 Loading: Recommended fluid: DOT 4 Maximum loading limit: Rear brake: 210.0 kg (463 lb) (Total weight of rider, cargo, accessories, and tongue) Type: Tire air pressure (measured on cold tires): Wet multiple disc brake Operation: Recommended: Left hand and right foot operation Front: Front suspension: 25.0 kPa (0.250 kgf/cm², 3.6 psi)
Page 159 Headlight: Ignition fuse: 10.0 A Bulb type: Auxiliary DC jack fuse: Krypton bulb Bulb voltage, wattage × quantity: 10.0 A Backup fuse: Headlight: 12 V, 30/30 W × 2 10.0 A Four-wheel-drive motor fuse: Tail/brake light: 10.0 A 12 V, 5.0/21.0 W × 1 Neutral indicator light: Reverse indicator light: Coolant temperature warning light:...
Page 160: Consumer Information
Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
Page 161 EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
Page 162 1. Model label 11-3...
Page 163 INDEX Accessories and loading ..........6-6 Differential gear oil ..........5-3, 8-24 Accessories, auxiliary jack ........... 4-23 Drive select lever ............4-13 Air filter element, cleaning ..........8-30 Drive select lever and driving in reverse ......6-3 Axle boots ..............8-45 Drive select lever safety system cable, adjusting ..
Page 164 Recoil starter ..............4-13 Reverse indicator light ............ 4-2 Identification numbers ..........11-1 Riding your ATV ............. 7-1 Indicator lights and warning light ........4-2 Instruments, lights and switches ........5-7 Safety information ............2-1 Seat ................4-18 Key identification number ..........11-1 Shock absorber assemblies, adjusting the front and rear ................
Page 165 Wheel, installing ............8-59 Wheel, removing ............8-59...
Page 166 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2009.06-0.3×1 CR...

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