Yamaha YFM4FGW Owner's Manual
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Yamaha YFM4FGW Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM4FGW
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-20-33
1P1-F8199-13

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Summary of Contents for Yamaha YFM4FGW

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM4FGW WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-20-33 1P1-F8199-13...
  • Page 2 EBU17091...
  • Page 3 Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

  • Page 4: Important Manual Information

    EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 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: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or...

  • Page 5: Important Notice

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

  • Page 6: Table Of Contents

    Throttle lever ..........4-6 EWB00010 WARNING Speed limiter ..........4-7 Front brake lever .........4-8 Indicates a potential hazard that could result in serious injury or death. Brake pedal and rear brake lever ....4-9 Drive select lever ........4-9 Recoil starter ..........4-10 Fuel tank cap ..........4-11 EBU17420 Fuel ............4-11 TABLE OF CONTENTS...
  • Page 7 Tires ............5-6 RIDING OVER ROUGH TERRAIN....7-29 Measuring the tire pressure ....... 5-7 SLIDING AND SKIDDING ......7-31 Tire wear limit ..........5-8 WHAT TO DO IF........7-32 Chassis fasteners ........5-9 WHAT TO DO..........7-32 Instruments, lights and switches ....5-9 PERIODIC MAINTENANCE AND OPERATION ..........
  • Page 8 Checking the stabilizer bushes ....8-46 CORPORATION, U.S.A. Lubricating the upper and lower ATV LIMITED WARRANTY ....11-5 arm pivots ..........8-46 YAMAHA EXTENDED SERVICE Lubricating the knuckle pivots ....8-46 (Y.E.S.) ...........11-7 Lubricating the knuckle shafts ....8-47 Lubricating the steering shaft ....8-47 Battery ............

  • Page 9: Safety Information

    EBU17430 SAFETY INFORMATION EBU17542 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 10 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 11 roll backwards, follow the special procedure for Always be sure there are no obstacles or people braking described in this manual. Dismount on behind you when you operate in reverse. When the uphill side or to a side if pointed straight up- it is safe to proceed in reverse, go slowly.
  • Page 12 EWB00021 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- POTENTIAL HAZARD oline in your eyes, seek medical help Improper handling of gasoline. immediately. If gasoline spills on your skin, WHAT CAN HAPPEN wash with soap and water.
  • Page 13 WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad- equate ventilation.

  • Page 14: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 15 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.

  • Page 18: 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. Storage compartment and tool kit 4. Throttle stop screw 4. Spark plug 5.

  • Page 19: Controls And Instruments

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

  • Page 20: Instrument And Control Functions

    EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17770 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights, meter lighting and taillight come on 1.

  • Page 21: Indicator Lights And Warning Light

    3. Push the start switch. If the warning light does not come on while the start switch is pushed, 1. Neutral indicator light “N” have a Yamaha dealer check the electrical cir- 2. Reverse indicator light “R” cuit. 3. Coolant temperature warning light “...

  • Page 22: Speedometer

    EBU17952 On-Command four-wheel-drive indicator light “ ” This indicator light comes on when the On-Com- mand four-wheel-drive switch is set to the “4WD” position. NOTE: Due to the synchronizing mechanism in the differ- ential gear case, the light may not come on until the ATV starts moving.

  • Page 23: Handlebar Switches

    EBU18060 Handlebar switches 1. Fuel gauge 2. Red line 1. Light switch “ /OFF” 2. Engine stop switch “ ” NOTE: 3. Start switch “ ” If the ATV runs out of fuel, move the fuel cock lever to the “RES” position. Approximately 4.5 L (1.19 EBU18080 US gal) (0.99 Imp.gal) of fuel will be remaining in Engine stop switch “...
  • Page 24 EBU18100 EBU18200 Start switch “ ” On-Command four-wheel-drive switch Push this switch to crank the engine with the start- “2WD”/“4WD” This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice-versa. ECB00050 CAUTION: Select the appropriate drive according to the ter- See the starting instructions on page 6-1 prior rain and the conditions.

  • Page 25: Throttle Lever

    WHAT CAN HAPPEN The ATV handles differently in two-wheel drive than in four-wheel drive in some cir- cumstances. Changing from two-wheel drive to four-wheel drive or from four-wheel drive to two-wheel drive while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and in- crease the risk of losing control and of caus- ing an accident.

  • Page 26: Speed Limiter

    Check the operation of the throttle lever be- fore you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. EBU18311 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 27: Front Brake Lever

    HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). (See page 8-36.) EBU18391 Front brake lever The front brake lever is located on the right handle- bar.

  • Page 28: Brake Pedal And Rear Brake Lever

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

  • Page 29: Recoil Starter

    1. Drive select lever 1. Recoil starter EWB00290 EBU18680 Recoil starter WARNING Firmly grasp the handle and pull slightly until en- POTENTIAL HAZARD gagement can be felt. Then pull forcefully, being Starting the engine without setting the drive careful not to pull the rope all the way out. select lever to the park position.

  • Page 30: Fuel Tank Cap

    EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Fuel level 2. Fuel tank filler tube Recommended fuel: 1. Fuel tank cap UNLEADED GASOLINE ONLY Fuel tank capacity: EBU18730 15.0 L (3.96 US gal) (3.30 Imp.gal) Fuel Fuel reserve amount: Make sure that there is sufficient fuel in the tank.

  • Page 31: Fuel Cock

    HOW TO AVOID THE HAZARD Your Yamaha engine has been designed to use Do not overfill the fuel tank. Be careful not to regular unleaded gasoline with a pump octane...
  • Page 32 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 33: Starter (Choke)

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

  • Page 34: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18941 Storage compartment Insert the projections on the front of the seat into The storage compartment is located under the the seat holders and push down on the seat at the seat.

  • Page 35: Front Carrier

    ECB00130 NOTE: CAUTION: There is a check hose at the bottom of the storage Do not store metal or sharply edged objects, compartment. If any water collects in this hose, re- like tools, in the storage compartment. If they move the hose, empty it, and then install it. must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartment.

  • Page 36: Rear Carrier

    Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspen- NOTE: sion, and in direction (b) to decrease the spring A special wrench can be obtained at a Yamaha preload and thereby soften the suspension. dealer to make this adjustment. 4-17...

  • Page 37: Auxiliary Dc Jack

    WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorber assem- blies on the left and right side to the same setting.
  • Page 38 Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A) 4. When the auxiliary DC jack is not being used, cover it with the cap. ECB00120 CAUTION: Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to 1.

  • Page 39: Pre-Operation Checks

    Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 40 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check lever free play, and adjust if necessary. Rear brake • Check brake pads for wear, and replace if necessary. 5-5, 8-37, 8-38, 8-41 •...
  • Page 41 WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Own- er’s Manual.

  • Page 42: Fuel

    EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. Make sure that the final gear oil is at the specified (See page 4-11.) level. Add oil as necessary. (See page 8-21.) EWB00500 WARNING EBU19600 Differential gear oil POTENTIAL HAZARD...

  • Page 43: Front And Rear Brakes

    Check that there is no free play in the front brake checked by a Yamaha dealer. lever. If there is free play, have a Yamaha dealer check the brake system. Check for correct free play in the rear brake le- ver.

  • Page 44: Throttle Lever

    America for this model. Other tire lem with the brakes. If a problem cannot be combinations are not recommended. corrected by the adjustment procedures pro- Front: vided in this manual, have a Yamaha dealer Manufacturer/model: check for the cause. MAXXIS/M979 Size:...

  • Page 45: Measuring The Tire Pressure

    Rear: Tire pressure below the minimum speci- Manufacturer/model: fied could cause the tire to dislodge from MAXXIS/M980 the rim under severe riding conditions. Size: Minimum tire pressure: AT25 x 10-12 Front: Type: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Tubeless Rear: The tires should be set to the recommend- 22.0 kPa (3.2 psi) (0.220 kgf/cm²) ed pressure:...

  • Page 46: Tire Wear Limit

    Recommended pressure: NOTE: Front The low-pressure tire gauge is included as stan- 25.0 kPa (3.6 psi) (0.250 kgf/cm²) dard equipment. Make two measurements of the Rear tire pressure and use the second reading. Dust or 25.0 kPa (3.6 psi) (0.250 kgf/cm²) dirt in the gauge could cause the first reading to be Minimum: incorrect.

  • Page 47: Chassis Fasteners

    1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.

  • Page 48: Operation

    Read the Owner’s Manual carefully. If there is prior to operating the engine for the first time. a control or function you do not understand, ask your Yamaha dealer. 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “...
  • Page 49 3. Shift the drive select lever into the neutral or Ambient temp./starter (choke) position park position. The corresponding indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. NOTE: The engine can be started under the following con-...

  • Page 50: Starting A Warm Engine

    If the battery is discharged, pull the recoil starter EBU20291 Starting a warm engine to start the engine. Follow the same procedure as for starting a cold 7. If the engine is started with the starter (choke) engine, with the exception that the starter (choke) in position (1), the starter (choke) should be is not required when the engine is warm.
  • Page 51 NOTE: should come on. If the indicator light does not The drive select lever cannot be shifted into or from come on, have a Yamaha dealer check the elec- reverse or park without applying the brake pedal. trical circuit. 1. Bring the ATV to a complete stop.

  • Page 52: Engine Break-In

    There is never a more important period in the life of If any engine trouble should occur during the your engine than the first 20 hours of riding. For engine break-in period, immediately have a this reason, you should read the following material Yamaha dealer check the ATV. carefully.

  • Page 53: Parking

    Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of gen- 1. Bring the ATV to a stop by applying the uine Yamaha accessories. Other accessories brakes.
  • Page 54 Yamaha to test all non- Never exceed the weight limits shown. An over- Yamaha accessories, nor control over their qual- loaded ATV can be unstable. ity or suitability. Choose a genuine Yamaha ac- MAXIMUM LOADING LIMIT...
  • Page 55 the weight on the hitch. If you are carrying cargo EWB00750 WARNING and towing a trailer, include the tongue weight in the maximum ATV load limit. POTENTIAL HAZARD Load cargo on the carriers as close to the center Overloading this ATV or carrying or towing of the ATV as possible.

  • Page 56: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 57: Getting To Know Your Atv

    EWB00010 ular attention to the safety information on pages WARNING 1-1–1-5. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. EBU21411 GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use.

  • Page 58: Ride With Care And Good Judgement

    Beginners should get training from a certified in- course offered by Yamaha. They should then structor. regularly practice the skills learned in the Become familiar with this ATV at slow speeds first, course and the operating techniques de- even if you are an experienced operator.
  • Page 59 WHAT CAN HAPPEN Use by children of ATVs that are not recom- mended for their age can lead to severe inju- ry or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.
  • Page 60 This ATV is designed to carry operator and car- go only – passengers prohibited. EWB00910 WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger.
  • Page 61 Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet EWB00920 WARNING that fits properly. You should also wear: POTENTIAL HAZARD eye protection (goggles or face shield) Operating this ATV without wearing an ap- gloves proved motorcycle helmet, eye protection boots and protective clothing.
  • Page 62 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. by the influence of alcohol or drugs. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.
  • Page 63 EWB00950 Do not operate at speeds too fast for your skills WARNING or the conditions. EWB00960 POTENTIAL HAZARD WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Operating this ATV at speeds too fast for Use of improper tires on this ATV, or opera- your skills or the conditions.
  • Page 64 Speed limiter Loading and accessories For riders less experienced with this model, the Use extra caution when riding the ATV with addi- throttle lever housing is equipped with a speed lim- tional loads, such as accessories or cargo. The iter. The speed limiter keeps the throttle from fully ATV’s handling may be adversely affected.
  • Page 65 EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
  • Page 66 During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op- Removing even one hand or foot can reduce eration, otherwise they may contact the rear your ability to control the ATV or could wheels. cause you to lose your balance and fall off of the ATV.
  • Page 67 Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo- nents designed for use on this ATV and should be installed and used according to instructions.

  • Page 68: Be Careful Where You Ride

    Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system.
  • Page 69 HOW TO AVOID THE HAZARD EWB01030 WARNING Always avoid paved surfaces, including sidewalks, driveways, parking lots and POTENTIAL HAZARD streets. 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 public street, road or highway, even a dirt or gravel one.
  • Page 70 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 71 HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. EWB01060 WARNING POTENTIAL HAZARD...

  • Page 72: Turning Your Atv

    Do not ride in areas posted “no trespassing”. be hot when riding and afterwards; do not allow Do not ride on private property without getting per- skin or clothing to come in contact with these com- mission. ponents. With the engine idling, return the starter (choke) to the closed position, and shift the drive select lever into the forward position.
  • Page 73 EWB01080 WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a colli- sion or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner’s Manual. Prac- tice turning at low speeds before attempting to turn at faster speeds.

  • Page 74: Climbing Uphill

    Improper riding procedures such as abrupt throttle WHAT CAN HAPPEN changes, excessive braking, incorrect body move- The ATV can overturn more easily on ex- ments, or too much speed for the sharpness of the tremely steep hills than on level surfaces or turn may cause the ATV to tip.
  • Page 75 HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing hills as described in this Owner’s Manu- Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly.
  • Page 76 If you are climbing a hill and you find that you have When crossing the side of a hill: not properly judged your ability to make it to the Always follow proper procedures as de- top, you should turn the ATV around while you still scribed in the Owner’s Manual.
  • Page 77 If you start to roll backwards, DO NOT apply either If you begin rolling backwards: brake abruptly. If you are in 2WD, apply only the Keep weight uphill. front brake. If you are in 4WD, because all wheels 2WD: Never apply the rear brake while roll- are interconnected by the drive train, applying ei- ing backwards.

  • Page 78: Riding Downhill

    RIDING DOWNHILL Whenever possible, ride your ATV straight down- When riding your ATV downhill, shift your weight hill. Avoid sharp angles which could allow the ATV as far to the rear and uphill side of the ATV as pos- to tip or roll over. Carefully choose your path and sible.
  • Page 79 7-24...

  • Page 80: Crossing A Slope

    CROSSING A SLOPE HOW TO AVOID THE HAZARD Traversing a sloping surface on your ATV requires Never attempt to turn the ATV around on any you to properly position your weight to maintain hill until you have mastered the turning tech- proper balance.
  • Page 81 7-26...

  • Page 82: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
  • Page 83 1. Air filter case check hose ECB00280 CAUTION: After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the storage compartment check hose.

  • Page 84: Riding Over Rough Terrain

    1. V-belt case drain plug 1. Drive select lever box check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident.
  • Page 85 WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.

  • Page 86: Sliding And Skidding

    SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.

  • Page 87: What To Do If

    WHAT CAN HAPPEN If your ATV begins to tip while turning: You may lose control of this ATV. You may Lean more into the turn to regain balance. If nec- also regain traction unexpectedly, which essary, gradually let off the throttle and/or steer may cause the ATV to overturn.
  • Page 88 If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let wa- ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability.

  • Page 89: Periodic Maintenance And Minor Repair

    Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.
  • Page 90 Yamaha ATV dealer. additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: 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

    EBU21863 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
  • Page 94 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Upper and lower √ √ √ • Lubricate with lithium-soap-based grease. arm pivots • Check for wear, cracks or other damage, and re- √...
  • Page 95 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Engine oil filter car- √ √ √ • Replace. tridge √ √ √ 22 * Engine oil strainer •...
  • Page 96 EBU23070 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 97: Removing And Installing Panels

    EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed.
  • 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. Bolt 2. Panel B To install the panel Place the panel in the original position and install the bolt. ECB00380 CAUTION: When installing the panel, be sure not to pinch 2.
  • Page 100 Panel C To remove the panel 1. Remove the carrier top bolts. 1. Carrier bolt (under the fenders) 3. Remove the quick fastener screws, and then pull the panel upward to remove it. 1. Carrier bolt (top) 2. Remove the carrier bolts under the fenders, and then take the carrier off.
  • Page 101 Panel E To remove the panel Remove the bolts, and then take the panel off. 1. Quick fastener screw 2. Panel C To install the panel 1. Place the panel in the original position, and 1. Panel E then install the quick fastener screws. 2.

  • Page 102: Checking The Spark Plug

    EBU23221 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart.
  • Page 103 Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 104: Engine Oil And Oil Filter Cartridge

    NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4.
  • Page 105 1. Engine oil filler cap 1. Dipstick 2. Maximum level mark 6. Insert the dipstick into the filler hole (without 3. Minimum level mark screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the minimum and maximum level marks.
  • Page 106 To change the engine oil (with or without oil fil- NOTE: ter cartridge replacement) Skip steps 6–10 if the oil filter cartridge is not being 1. Remove panel F. (See page 8-9.) replaced. 2. Place the ATV on a level surface. 6.
  • Page 107 1. Oil filter wrench 1. O-ring NOTE: NOTE: An oil filter wrench is available at a nearby Yamaha Make sure that the O-ring is properly seated. dealer. 9. Install the new oil filter cartridge with an oil fil- 8. Apply a thin coat of engine oil to the O-ring of ter wrench, and then tighten it to the specified the new oil filter cartridge.
  • Page 108 12. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.43 US qt) (2.02 Imp.qt) With oil filter cartridge replacement: 2.40 L (2.54 US qt) (2.11 Imp.qt) 1.

  • Page 109: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified 1.
  • Page 110 To change the final gear oil 1. Remove the engine guard and the final gear case guard by removing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 1.

  • Page 111: Changing The Differential Gear Oil

    CAUTION: leakage before each ride. If any leakage is found, Be sure no foreign material enters the final have a Yamaha dealer check and repair the ATV. gear case. In addition, the differential gear oil must be 7. Install the oil filler bolt, and then tighten it to the changed as follows at the intervals specified in the specified torque.
  • Page 112 2. Place an oil pan under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case. 1. Differential gear oil drain bolt 4.

  • Page 113: Coolant

    The differential gear case capacity is greater EBU23470 Coolant than the recommended oil quantity, therefore The coolant level should be checked before each the oil level cannot be accurately checked from ride. In addition, the coolant must be changed at the oil filler hole.
  • Page 114 If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- 1. Coolant reservoir cap tent of the coolant as soon as possible, oth- 2.
  • Page 115 EBU23592 To change the coolant EWB01880 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing 1.
  • Page 116 4. Remove the front carrier and panel C. (See page 8-9.) 5. Remove the radiator cap. 1. Coolant reservoir hose 9. After draining the coolant, thoroughly flush the cooling system with clean tap water. 1. Radiator cap 10. Replace the coolant drain bolt washer if it is damaged, install the coolant drain bolt, and 6.

  • Page 117: Cleaning The Air Filter Element

    Coolant reservoir capacity (up to the maxi- leakage. mum level mark): 0.25 L (0.26 US qt) (0.22 Imp.qt) NOTE: If any leakage is found, have a Yamaha dealer ECB00401 check the cooling system. CAUTION: 17. Install the panels and the front carrier.
  • Page 118 NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air fil- ter case. 1. Air filter case holder 2.
  • Page 119 1. Air filter element 1. Air filter element frame 2. Sponge material 4. Pull off the lock plate, and then remove the 3. Air filter element lock plate sponge material from the air filter element 5. Wash the sponge material gently but thor- frame.
  • Page 120 CAUTION: damaged. Make sure that the air filter element is prop- 8. Apply Yamaha foam air filter oil or other qual- erly seated in the air filter case. ity foam air filter oil to the sponge material. Never operate the engine with the air filter el- NOTE: ement removed.

  • Page 121: Cleaning The Spark Arrester

    will affect carburetor jetting with subsequent 3. Tap the tailpipe lightly, and then use a wire poor performance and possible engine over- brush to remove any carbon deposits from the heating. spark arrester portion of the tailpipe and inside of the tailpipe housing. EBU23881 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be-...

  • Page 122: V-Belt Cooling Duct Check Hose

    If water drains from the V-belt case after removing If dust or water collects in the V-belt cooling duct the plug, have a Yamaha dealer check the ATV as check hose, remove the hose and clean it. the water may affect other engine parts.

  • Page 123: Adjusting The Carburetor

    ECB00480 CAUTION: The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performance of or damage to the engine. EBU24010 Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals 1.

  • Page 124: Adjusting The Throttle Cable Free Play

    (a). To decrease Engine idling speed: the throttle cable free play, turn the adjusting 1450–1550 r/min bolt in direction (b). NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 8-36...

  • Page 125: Valve Clearance

    (0.04 in), have a Yamaha dealer replace the brake prevent this from occurring, the valve clearance pads as a set. must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.

  • Page 126: Checking The Brake Fluid Level

    Yamaha dealer replace the brake pads as a set. 1. Lining thickness NOTE: The wheels need to be removed to check the 1. Wear indicator groove brake pads. (See page 8-55.)
  • Page 127 Before riding, check that the brake fluid is above Rear brake the minimum level mark and replenish if neces- sary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.

  • Page 128: Changing The Brake Fluid

    Water will signifi- free play of zero mm (zero in) as shown. If the free cantly lower the boiling point of the fluid and may play is incorrect, have a Yamaha dealer check the result in vapor lock. brake system.

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

    Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU27130 Adjusting the rear brake lever free play and checking the brake pedal position...
  • Page 130 The top of the brake pedal should be positioned 72.0 mm (2.83 in) above the top of the footboard. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 1. Locknut 2. Brake lever free play adjusting bolt 3.

  • Page 131: Axle Boots

    Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24230 1. Front axle boot (each side) Axle boots...

  • Page 132: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. 1. Remove panel B. (See page 8-9.) NOTE: 1. Brake light switch The brake light switch is properly adjusted when 2.

  • Page 133: Checking And Lubricating The Front And Rear Brake Levers

    EWB02120 WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged, and cables can also be- come frayed or kinked, which could restrict the operation of controls and lead to an acci- dent or injury.

  • Page 134: Checking The Wheel Bearings

    Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bush- es if necessary. EBU25040 Lubricating the upper and lower arm...

  • Page 135: Lubricating The Knuckle Shafts

    EBU25100 Recommended lubricant: Lubricating the steering shaft Lithium-soap-based grease The steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Recommended lubricant: Lithium-soap-based grease EBU25212 Battery This model is equipped with a sealed-type (MF) battery, which does not require any maintenance.
  • Page 136 EWB02140 To charge the battery WARNING Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in POTENTIAL HAZARD mind that the battery tends to discharge more Failure to handle batteries or battery electro- quickly if the ATV is equipped with optional electri- lyte carefully.

  • Page 137: Replacing A Fuse

    To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat- tery. 8-49...
  • Page 138 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. Spare fuse The main fuse and the fuse box are located under the seat. (See page 4-14.) If a fuse is blown, replace it as follows.

  • Page 139: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical Specified fuses: circuits to check if the devices operate. Main fuse: 4. If the fuse immediately blows again, have a 30.0 A Yamaha dealer check the electrical system. Headlight fuse: EBU26892 15.0 A Replacing a headlight bulb Ignition fuse: If a headlight bulb burns out, replace it as follows.
  • Page 140 3. Remove the headlight bulb holder assembly by turning it counterclockwise. 1. Cover at the rear of the headlight 2. Disconnect the headlight coupler by lifting the 1. Headlight bulb holder assembly tab as shown and pulling out the coupler. NOTE: The headlight bulb cannot be removed from the headlight bulb holder.

  • Page 141: Adjusting A Headlight Beam

    7. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam 1. Do not touch the glass part of the bulb. ECB00690 CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 8-53...

  • Page 142: Replacing The Tail/Brake Light Bulb

    To raise a headlight beam, turn the adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b). 1. Tail/brake light assembly 2. Nut 2. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 1.

  • Page 143: Removing A Wheel

    1. Tail/brake light assembly 1. Tail/brake light bulb holder 2. Tail/brake light bulb holder 2. Tail/brake light bulb 3. Remove the defective bulb by pushing it in 4. Insert a new bulb into the bulb holder, push it and turning it counterclockwise. in, and then turn it clockwise until it stops.

  • Page 144: Installing A Wheel

    Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Wheel nut 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 1.
  • Page 145 1. Tapered nut 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques. Tightening torques: Front wheel nut: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear wheel nut: 55 Nm (5.5 m·kgf, 40 ft·lbf) 8-57...

  • Page 146: 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 147: 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 148 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: 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 149: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25870 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 150: Storage

    EWB02300 To prevent corrosion, avoid damp cellars, WARNING stables (because of the presence of ammo- nia) and areas where strong chemicals are POTENTIAL HAZARD stored. Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping abil- Long-term ity, increasing the chance of an accident.
  • Page 151 b. Pour a teaspoonful of engine oil into the sively cold or warm place [less than 0 °C (30 spark plug bore. °F) or more than 30 °C (90 °F)]. For more in- c. Install the spark plug cap onto the spark formation on storing the battery, see page plug, and then place the spark plug on the 8-47.

  • Page 152: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 10.50 :1 Overall length: Starting system: 1993 mm (78.5 in) Electric and recoil starter Overall width: Lubrication system: 1093 mm (43.0 in) Wet sump Overall height: Engine oil: 1120 mm (44.1 in) Seat height: Type: 830 mm (32.7 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase:...
  • Page 153 With oil filter cartridge replacement: Type x quantity: 2.40 L (2.54 US qt) (2.11 Imp.qt) BSR33 x 1 Final gear oil: Spark plug (s): Type: Manufacturer/model: SAE80 API GL-4 Hypoid gear oil NGK/DR8EA Quantity: Spark plug gap: 0.16 L (0.17 US qt) (0.14 Imp.qt) 0.6–0.7 mm (0.024–0.028 in) Differential gear oil: Clutch:...
  • Page 154 Trail: Maximum: 8.5 mm (0.33 in) Front: Front tire: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Rear: Type: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Tubeless Front wheel: Size: AT25 x 8-12 Wheel type: Manufacturer/model: Panel wheel MAXXIS/M979 Rim size: Rear tire: 12 x 6.0AT Rear wheel: Type:...
  • Page 155 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Meter lighting: Double wishbone 14 V, 3.0 W × 1 Spring/shock absorber type: Neutral indicator light: Coil spring/oil damper 12 V, 1.7 W × 1 Wheel travel: Reverse indicator light: 160 mm (6.3 in) 12 V, 1.7 W ×...

  • Page 156: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 157 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 158: Noise Regulation

    EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ul- timate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 159: Maintenance Record

    EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 160: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 161 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 162: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”...
  • Page 163 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 164 EBU26132 11-9...
  • Page 165 INDEX Accessories and loading ..........6-6 Differential gear oil ............5-4 Accessories, auxiliary jack ........... 4-18 Differential gear oil, changing ........8-23 Air filter element, cleaning ..........8-29 Drive select lever ............4-9 Axle boots ..............8-43 Drive select lever and driving in reverse ......6-3 Drive select lever safety system cable, adjusting ..
  • Page 166 Identification numbers ..........11-1 Recoil starter ..............4-10 Indicator lights and warning light ........4-2 Reverse indicator light ............ 4-2 Instruments, lights and switches ........5-9 Riding your ATV ............. 7-1 Key identification number ..........11-1 Safety information ............1-1 Knuckle pivots, lubricating ..........
  • Page 167 Valve clearance ............8-37 V-belt case drain plug ..........8-34 V-belt cooling duct check hose ........8-34 Vehicle identification number ........11-1 Warranty, extended ............11-7 Warranty, limited ............11-5 Wheel bearings, checking ..........8-46 Wheel, installing ............8-56 Wheel, removing ............8-55...
  • Page 168 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN USA 2006.05-0.5×1 CR...

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