Instruction/ maintenance manual of the product yfz 450r Yamaha
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This A OWNER’S MANUAL LIT -1 1626-22-75 18P-28199-10 This ATV should not be ridden by anyone under 16 years of age. YFZ450RY WARNING READ THIS MANUAL CAREFULLY! It contains important safety information.
EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold..
EBU17170 INTRODUCTION EBU17301 Congratulations on your purchase of the Yamaha YFZ450RY. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines.
EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: * Product and specifications are subject to change without notice.
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.
W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU17420 TABLE OF CONTENTS SAFETY INFORMATION .............................. 1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................
OPERATION .................................................. 6-1 Starting the engine .................................... 6-1 Shifting ...................................................... 6-2 Engine break-in .........................................
Lubricating the swingarm pivots .............. 8-43 Lubricating the upper and lower arm pivots ..................................................... 8-44 Battery ..................................................... 8-45 Replacing the fuse ...........
1-1 1 2 3 4 5 6 7 8 9 10 11 EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU29350 AN ATV IS NOT A TOY AND CAN BE HAZARD- OUS TO OPERATE. An ATV handles differently from other vehicles, in- cluding motorcycles and cars.
1-2 1 2 3 4 5 6 7 8 9 10 11 that is proper for the terrain, visibility, operating conditions, and your experience. ● Never attempt wheelies, jumps, or other stunts. ● Always inspect your ATV each time you use it to make sure it is in safe operating condition.
1-3 1 2 3 4 5 6 7 8 9 10 11 ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill.
1-4 1 2 3 4 5 6 7 8 9 10 11 EWB02320 EWB00030 W ARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot.
2-1 1 2 3 4 5 6 7 8 9 10 11 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 5 6 3 2 1 6 4.
2-2 1 2 3 4 5 6 7 8 9 10 11 EBU17670 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.
2-3 1 2 3 4 5 6 7 8 9 10 11 W ARNING UNDER 16 NEVER operate this A TV if y ou are under age 16 . 1 W ARNING Improper A TV use can result in SEVERE INJUR Y or DEA TH.
2-4 1 2 3 4 5 6 7 8 9 10 11 WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. Do not incinerate, puncture or open. 4AA-22259-80 W ARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
3-1 1 2 3 4 5 6 7 8 9 10 11 EBU17680 DESCRIPTION EBU17690 Left view EBU17700 Right view 1. F ront shock absorber assemb ly compression damping force adjusting bolt (f or f ast compression damping) 2. F ront shock absorber assemb ly compression damping force adjusting scre w (f or slow compression damping) 3.
3-2 1 2 3 4 5 6 7 8 9 10 11 EBU17712 Controls and instruments TIP The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Clutch le v er 2. P arking brake le ver 3. Left handlebar s witches 4. Fuel tank cap 5. Main s witch 6.
4-1 1 2 3 4 5 6 7 8 9 10 11 EBU17724 INSTRUMENT AND CONTROL FUNCTIONS W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU17760 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power.
4-2 1 2 3 4 5 6 7 8 9 10 11 EBU29380 Indicator light and warning lights EBU17860 Neutral indicator light “” This indicator light comes on when the transmis- sion is in the neutral position. EBU26700 Coolant temperature warning light “” This warning light comes on when the engine over- heats.
4-3 1 2 3 4 5 6 7 8 9 10 11 EBU26720 Engine trouble warning light “” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system. The electrical circuit of the warning light can be checked by turning the key to “ON”.
4-4 1 2 3 4 5 6 7 8 9 10 11 turned off for an extended period of time, oth- erwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. EBU18270 Throttle lever Once the engine is running, movement of the throt- tle lever will increase the engine speed.
4-5 1 2 3 4 5 6 7 8 9 10 11 EBU18311 Speed limiter Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum.
4-6 1 2 3 4 5 6 7 8 9 10 11 EWB00190 EBU18382 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporat- ed in the clutch lever holder. To disengage the clutch, pull the clutch lever toward the handlebar grip.
4-7 1 2 3 4 5 6 7 8 9 10 11 EBU18432 Brake pedal The brake pedal is located on the right side of the ATV. To apply the rear brake, push down on the brake pedal. EBU18510 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope.
4-8 1 2 3 4 5 6 7 8 9 10 11 EWB00170 EBU18530 Shift pedal This ATV is equipped with a constant-mesh 5- speed transmission. The shift pedal is located on the left side of the engine and is used in combina- tion with the clutch when shifting. 1. P arking brake le ver (loc ked position) 1.
4-9 1 2 3 4 5 6 7 8 9 10 11 EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. EBU18800 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 1. Shift pedal 1 1.
4-10 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00070 Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.
4-11 1 2 3 4 5 6 7 8 9 10 11 EBU18890 Seat To remove the seat Insert your hand between the rear of the seat and the rear fender, pull the seat lock lever upward and pull up the seat at the rear. To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear.
4-12 1 2 3 4 5 6 7 8 9 10 11 EBU29291 Adjusting the front shock absorber assemblies These shock absorber assemblies are equipped with a spring preload adjusting nut, a rebound damping force adjusting .
4-13 1 2 3 4 5 6 7 8 9 10 11 the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension. TIP ● A special wrench can be obtained at a Yamaha dealer to make this adjustment. ● The spring preload setting is determined by measuring distance A, shown in the illustration.
4-14 1 2 3 4 5 6 7 8 9 10 11 3. Tighten the locknut to the specified torque. NOTICE ECB00080 Always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque.
4-15 1 2 3 4 5 6 7 8 9 10 11 Compression damping force Compression damping force (for fast compression damping) To increase the compression damping force and thereby harden the compression damping, turn the adjusting bolt in direction (a).
4-16 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00090 Never turn an adjusting mechanism beyond the minimum and maximum settings. TIP Although the total number of clicks of a damping force adjusting mechanism m.
4-17 1 2 3 4 5 6 7 8 9 10 11 EWB00350 EBU29512 Adjusting the rear shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting nut, a rebound damping force adjustin.
4-18 1 2 3 4 5 6 7 8 9 10 11 Spring preload 1. Remove panel C. (See page 8-8.) 2. Loosen the clamp screw at the throttle body side, and then disconnect the air intake duct from the throttle body. 3. Disconnect the coupler. 4. Loosen the clamp screw at the air filter case side, and then disconnect the air intake duct from the air filter case.
4-19 1 2 3 4 5 6 7 8 9 10 11 5. Remove the air filter case holding plate by re- moving the bolts and collars. 6. Remove the blow-by gas chamber by remov- ing the bolt.
4-20 1 2 3 4 5 6 7 8 9 10 11 7. Remove the air filter case by removing the bolts. 8. Loosen the locknut. 9. Turn the adjusting nut in direction (a) to in- crease the spring preload and thereby harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension.
4-21 1 2 3 4 5 6 7 8 9 10 11 TIP ● A special wrench can be obtained at a Yamaha dealer to make this adjustment. ● The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the higher the spring preload; the longer distance A is, the lower the spring preload.
4-22 1 2 3 4 5 6 7 8 9 10 11 10. Tighten the locknut to the specified torque. NOTICE ECB00080 Always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque. 11. Place the air filter case in the original position, install the bolts, and then tighten them to the specified torque.
4-23 1 2 3 4 5 6 7 8 9 10 11 rebound damping force and thereby soften the damping. TIP Make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting. Compression damping force Panels A and D need to be removed to make this adjustment.
4-24 1 2 3 4 5 6 7 8 9 10 11 Compression damping force (for slow compres- sion damping) To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b).
4-25 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00090 Never turn an adjusting mechanism beyond the minimum and maximum settings. TIP ● Make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting(s).
4-26 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. 1. Handlebar 1.
5-1 1 2 3 4 5 6 7 8 9 10 11 EBU19200 PRE-OPERATION CHECKS EBU19213 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. EWB00470 TIP The maintenance of some items in the table has to be performed by a Yamaha dealer.
5-2 1 2 3 4 5 6 7 8 9 10 11 ITEM ROUTINE P A GE Fuel ● Check fuel le v el in fuel tank, and add recommended fuel if neces- sary . ● Check fuel line f or leakage. Correct if necessar y . 4-9, 5-4 Engine oil ● Check oil le v el in engine, and add recommended oil to specified lev el if necessary .
5-3 1 2 3 4 5 6 7 8 9 10 11 Wheels and tires ● Check wheel condition, and replace if damaged. ● Check tire condition and tread depth. Replace if necessar y . ● Check air pressure . Correct if necessary . 5-6, 5-7, 5-8 Shift pedal ● Make sure that operation is smooth.
5-4 1 2 3 4 5 6 7 8 9 10 11 EBU19530 Fuel Make sure that there is sufficient fuel in the tank. (See page 4-9.) EWB00500 EBU19560 Engine oil Make sure that the engine oil is at the specified lev- el. Add oil as necessary. (See page 8-14.) EBU19620 Coolant Make sure that the coolant is at the specified level.
5-5 1 2 3 4 5 6 7 8 9 10 11 EBU19700 Front and rear brakes Brake lever and brake pedal ● Check that there is no free play in the brake le- ver. If there is free play, have a Yamaha dealer check the brake system. ● Check for correct brake pedal height.
5-6 1 2 3 4 5 6 7 8 9 10 11 necessary. EBU19770 Drive chain Check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the drive chain as necessary. (See page 8-38.) EBU19782 Tires EWB00562 W ARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure.
5-7 1 2 3 4 5 6 7 8 9 10 11 EBU19821 Measuring the tire pressure Use the low-pressure tire gauge. TIP The low-pressure tire gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.
5-8 1 2 3 4 5 6 7 8 9 10 11 Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened.
6-1 1 2 3 4 5 6 7 8 9 10 11 EBU19871 OPERATION W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU19890 EWB00610 EBU29472 Starting the engine EWB00620 NOTICE ECB00150 See the “ Engine break-in ” section on page 6-4 prior to operating the engine for the first time.
6-2 1 2 3 4 5 6 7 8 9 10 11 level warning light and engine trouble warning light should come on, then go off. If a warning light does not go off, see page 4-2 for the corresponding warning light circuit check.
6-3 1 2 3 4 5 6 7 8 9 10 11 EBU20580 To start out and accelerate 1. Release the throttle lever, and then release the parking brake. NOTICE ECB00200 Always close the throttle before shifting gears, otherwise damage to the engine and drive train may result.
6-4 1 2 3 4 5 6 7 8 9 10 11 tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an accident.
6-5 1 2 3 4 5 6 7 8 9 10 11 operation or any condition that might result in en- gine overheating must be avoided. 0 – 160 km (0 – 100 mi) or 0 – 10 hours Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position.
6-6 1 2 3 4 5 6 7 8 9 10 11 EBU20850 Parking on a slope EWB00790 1. Bring the ATV to a stop by applying the brakes in first gear. 2. Stop the engine and release the clutch lever. 3. With the rear brake applied, apply the parking brake and slowly release the brake pedal.
6-7 1 2 3 4 5 6 7 8 9 10 11 ity or suitability. Choose a genuine Yamaha ac- cessory, or one that is equivalent in design and quality. ● Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV.
6-8 1 2 3 4 5 6 7 8 9 10 11 takes longer to stop. ● Avoid making sharp turns unless at very slow speeds. ● Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. EWB00750 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death.
7-1 1 2 3 4 5 6 7 8 9 10 11 EBU21131 RIDING YOUR ATV.
7-2 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU21593 GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by expe- rienced operators only.
7-3 1 2 3 4 5 6 7 8 9 10 11 Riding your ATV requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Not recommended for children under 16 years of age.
7-4 1 2 3 4 5 6 7 8 9 10 11 This ATV is designed to carry operator only – passengers prohibited. EWB00910 Apparel EWB00920 W ARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV.
7-5 1 2 3 4 5 6 7 8 9 10 11 Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci- dent.
7-6 1 2 3 4 5 6 7 8 9 10 11 EWB00930 Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety. EWB00940 EWB00950 W ARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs.
7-7 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. EWB00960 Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a speed lim- iter.
7-8 1 2 3 4 5 6 7 8 9 10 11 Loading and accessories As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add ac- cessories so that you can carry cargo or tow a trail- er, you must use common sense and good judgment.
7-9 1 2 3 4 5 6 7 8 9 10 11 During operation Always keep your feet on the footboards during op- eration, otherwise they may contact the rear wheels. EWB00980 Avoid wheelies and jumping. You may lose control of the ATV or overturn. EWB00990 W ARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation.
7-10 1 2 3 4 5 6 7 8 9 10 11 Modifications EWB01000 Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it.
7-11 1 2 3 4 5 6 7 8 9 10 11 BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. EWB01020 HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover.
7-12 1 2 3 4 5 6 7 8 9 10 11 Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. EWB01030 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset.
7-13 1 2 3 4 5 6 7 8 9 10 11 EWB01040 W ARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.
7-14 1 2 3 4 5 6 7 8 9 10 11 EWB01050 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. W ARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain.
7-15 1 2 3 4 5 6 7 8 9 10 11 EWB01060 Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders.
7-16 1 2 3 4 5 6 7 8 9 10 11 the shift pedal. Remember that the engine and ex- haust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then release the parking brake.
7-17 1 2 3 4 5 6 7 8 9 10 11 EWB01070 TURNING YOUR ATV To achieve maximum traction while riding off-road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. There- fore, unless the wheel on the inside of the turn is al- lowed to slip or lose some traction, the ATV will resist turning.
7-18 1 2 3 4 5 6 7 8 9 10 11 This procedure should be practiced at slow speed many times in a large off-road area with no obsta- cles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesn’t turn, come to a stop and then practice the proce- dure again.
7-19 1 2 3 4 5 6 7 8 9 10 11 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars.
7-20 1 2 3 4 5 6 7 8 9 10 11 If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.
7-21 1 2 3 4 5 6 7 8 9 10 11 If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the up- hill side.
7-22 1 2 3 4 5 6 7 8 9 10 11 RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- sible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the en- gine compression to do most of the braking for you.
7-23 1 2 3 4 5 6 7 8 9 10 11 CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface.
7-24 1 2 3 4 5 6 7 8 9 10 11 steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path.
7-25 1 2 3 4 5 6 7 8 9 10 11 depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and care- fully. EWB01150 Test your brakes after leaving the water.
7-26 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00240 After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions.
7-27 1 2 3 4 5 6 7 8 9 10 11 SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident.
7-28 1 2 3 4 5 6 7 8 9 10 11 With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are re- duced.
7-29 1 2 3 4 5 6 7 8 9 10 11 Lean more into the turn to regain balance. If nec- essary, gradually let off the throttle and/or steer to the outside of the turn. (See page 7-17.) ● If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room.
8-1 1 2 3 4 5 6 7 8 9 10 11 EBU21648 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21660 Safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your ATV in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages.
8-2 1 2 3 4 5 6 7 8 9 10 11 The service information included in this manual and the tools provided in the owner’s tool kit are in- tended to assist you in the performance of preven- tive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.
8-3 1 2 3 4 5 6 7 8 9 10 11 EBU21743 Periodic maintenance chart for the emission control system TIP ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals.
8-4 1 2 3 4 5 6 7 8 9 10 11 EBU21864 General maintenance and lubrication chart NO . ITEM CHECK OR MAINTENANCE JOB INITIAL EVER Y Whiche v- er comes fi rst month 1366 1 2 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 Air fi lter element ● Clean and replace if necessary .
8-5 1 2 3 4 5 6 7 8 9 10 11 10 * Swingarm pivots ● Check operation and f or e xcessive pla y , and replace bearings if necessar y . ● Lubricate with lithium-soap-based grease. √√√ 11 * Upper and lower arm pivots ● Lubricate with lithium-soap-based grease.
8-6 1 2 3 4 5 6 7 8 9 10 11 20 Engine oil ● Change. ● Check A TV f or oil leakage, and correct if neces- sary . √ √√√ 21 Engine oil fi lter ele- ment ● Replace. √√√ 22 Cooling system ● Check coolant le v el and A TV for coolant leakage, and correct if necessary .
8-7 1 2 3 4 5 6 7 8 9 10 11 EBU29430 TIP ● Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● Replace the fuel hose every five years and if cracked or damaged. ● Hydraulic brake service ● Regularly check and, if necessary, correct the brake fluid level.
8-8 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter.
8-9 1 2 3 4 5 6 7 8 9 10 11 4. Remove the quick fasteners, and then slide the panel backward and pull upward. To install the panel 1. Place the panel in the original position, and then install the quick fasteners.
8-10 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00380 When installing the panel, be sure not to pinch the cables or wires. 2. Install the bolts. 3. Install the fuel tank cap. Panels B and D To remove one of the panels 1. Remove panel A. 2. Pull the panel off. To install one of the panels 1.
8-11 1 2 3 4 5 6 7 8 9 10 11 2. Install panel A. Panel C To remove the panel 1. Remove panels A, B and D. 2. Remove the bolts, and then take the panel off. To install the panel Place the panel in its original position, and then in- stall the bolts. Panel E To remove the panel 1.
8-12 1 2 3 4 5 6 7 8 9 10 11 To install the panel 1. Place the panel in the original position and in- stall the bolts. 2. Install panel A. Panel F To remove the panel 1. Remove panel E. 2. Remove the bolts, and then take the panel off. To install the panel 1.
8-13 1 2 3 4 5 6 7 8 9 10 11 2. Install panel E. EBU29440 Checking the spark plug The spark plug is an important engine component, which should be checked periodically, preferably by a Yamaha dealer.
8-14 1 2 3 4 5 6 7 8 9 10 11 TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
8-15 1 2 3 4 5 6 7 8 9 10 11 and maximum level marks. 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type through the engine oil tank filler hole to raise it to the correct level.
8-16 1 2 3 4 5 6 7 8 9 10 11 6. Remove the engine oil tank filler cap and the engine oil tank drain bolt. 7. Check the washers for damage, and replace if necessary. TIP Skip steps 8–11 if the oil filter element is not being replaced. 8. Remove the oil filter element cover by remov- ing the bolts, and then remove the oil filter el- ement.
8-17 1 2 3 4 5 6 7 8 9 10 11 9. Check the O-rings for damage, and replace them if necessary. 10. Install a new oil filter element and the O-rings. TIP Make sure that the O-rings are properly seated. 11. Install the oil filter element cover by installing the bolts, and then tighten them to the speci- fied torque.
8-18 1 2 3 4 5 6 7 8 9 10 11 12. Install the crankcase engine oil drain bolt and the engine oil tank drain bolt, and then tighten them to their specified torques. 13. Pour the specified amount of the recommend- ed engine oil through the engine oil tank filler hole, and then install and tighten the engine oil tank filler cap.
8-19 1 2 3 4 5 6 7 8 9 10 11 minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 15. Turn the engine off, and then check the oil lev- el and correct it if necessary. 16. Install the engine guard by installing the bolts, and then tighten them to the specified torque.
8-20 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00401 ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard wa- ter or salt water since it is harmful to the en- gine.
8-21 1 2 3 4 5 6 7 8 9 10 11 EBU23551 To change the coolant EWB01880 1. Place the ATV on a level surface. 2. Remove panel F. (See page 8-8.) 3. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object as shown.
8-22 1 2 3 4 5 6 7 8 9 10 11 5. Remove the coolant reservoir by removing the bolts. 6. Remove the coolant reservoir cap, and then turn the coolant reservoir upside down to empty it. 7. After draining the coolant, thoroughly flush the cooling system with clean tap water.
8-23 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00401 ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard wa- ter or salt water since it is harmful to the en- gine.
8-24 1 2 3 4 5 6 7 8 9 10 11 1. Place the ATV on a level surface. 2. Remove the seat. (See page 4-11.) 3. Remove the air filter case cover by unhooking the holders. 4. Loosen the wing bolt. 5. Remove the air filter element together with the wing bolt and washer.
8-25 1 2 3 4 5 6 7 8 9 10 11 6. Remove the wing bolt and washer from the air filter element. 7. Remove the sponge material from the air filter element frame. 8. Wash the sponge material gently but thor- oughly in solvent. EWB01900 1. Wing bolt 2. Air filter element 1 2 1.
8-26 1 2 3 4 5 6 7 8 9 10 11 9. Squeeze the excess solvent out of the sponge material and let it dry. NOTICE ECB00440 Do not twist the sponge material when squeez- ing it. 10. Check the sponge material and replace it if damaged. 11. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material.
8-27 1 2 3 4 5 6 7 8 9 10 11 14. Insert the air filter element into the air filter case, and then tighten the wing bolt. 15. Install the air filter case cover by hooking the holders onto the air filter case. 16. Install the seat. TIP The air filter element should be cleaned every 20– 40 hours.
8-28 1 2 3 4 5 6 7 8 9 10 11 brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the bolt and tighten it to the specified torque.
8-29 1 2 3 4 5 6 7 8 9 10 11 EWB01930 EBU24045 Adjusting the throttle cable free play The throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in the periodic maintenance and lubrication chart. The throttle cable free play should measure 2.
8-30 1 2 3 4 5 6 7 8 9 10 11 4. Tighten the locknut. 5. Slide the rubber cover to its original position. EBU24060 Valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise.
8-31 1 2 3 4 5 6 7 8 9 10 11 TIP The wheels need to be removed to check the brake pads. (See page 8-50.) EBU26460 Rear brake pads Each rear brake pad is provided with wear indica- tor grooves, which allow you to check the brake pad wear without having to disassemble the brake.
8-32 1 2 3 4 5 6 7 8 9 10 11 brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Front brake Rear brake TIP To check the rear brake fluid level, remove the seat.
8-33 1 2 3 4 5 6 7 8 9 10 11 ● Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. ● Be careful that water does not enter the brake fluid reservoir when refilling.
8-34 1 2 3 4 5 6 7 8 9 10 11 EBU24601 Checking the brake pedal position The brake pedal position must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The top of the brake pedal should be positioned 11.
8-35 1 2 3 4 5 6 7 8 9 10 11 EWB02060 EBU24700 Adjusting the parking brake free play The parking brake free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Cable length “A” should measure 47–51 mm (1.
8-36 1 2 3 4 5 6 7 8 9 10 11 TIP If the cable length cannot be adjusted to specifica- tion, consult a Yamaha dealer. 5. Tighten the locknut on the brake cable. 6. Turn in the adjusting bolt at the rear brake cal- iper until it feels tight, then turn it out 1/8 turn and tighten its locknut to the specified torque.
8-37 1 2 3 4 5 6 7 8 9 10 11 vals specified in the periodic maintenance and lu- brication chart. The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer.
8-38 1 2 3 4 5 6 7 8 9 10 11 1. To increase the clutch lever free play, turn the adjusting nut at the clutch lever in direction (a), and to decrease it, turn the nut in direction (b). If the specified free play cannot be obtained, proceed with the following steps.
8-39 1 2 3 4 5 6 7 8 9 10 11 To check the drive chain slack 1. Place the ATV on a level surface. TIP When checking and adjusting the drive chain slack, there should be no weight on the ATV and all tires must be touching the ground.
8-40 1 2 3 4 5 6 7 8 9 10 11 TIP A rod can be obtained at a Yamaha dealer to make this adjustment. 4. Shift the transmission into neutral. 5. To tighten the drive chain, push the ATV back- ward.
8-41 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00560 The drive chain must be lubricated after wash- ing the ATV or riding in the rain. 1. Clean the drive chain with kerosene and a small soft brush. NOTICE ECB00570 To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pres- sure washers or inappropriate solvents.
8-42 1 2 3 4 5 6 7 8 9 10 11 EWB02120 EBU24922 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Brake lever Clutch lever W ARNING POTENTIAL HAZARD Damaged control cables.
8-43 1 2 3 4 5 6 7 8 9 10 11 EBUM0170 Checking the shift pedal The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle.
8-44 1 2 3 4 5 6 7 8 9 10 11 EBU25032 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun.
8-45 1 2 3 4 5 6 7 8 9 10 11 Right side EBU29172 Battery This model is equipped with a VRLA (Valve Regu- lated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened.
8-46 1 2 3 4 5 6 7 8 9 10 11 To remove the battery 1. Remove the seat. (See page 4-11.) 2. Remove the battery holding plate by removing the bolts. 3. Disconnect the negative battery lead first, then the positive battery lead by removing their bolt. 4.
8-47 1 2 3 4 5 6 7 8 9 10 11 charged battery can cause permanent battery damage. To install the battery TIP Be sure the battery is fully charged. 1. Place the battery in its compartment. 2. Connect the positive battery lead first, then the negative battery lead by installing their bolt.
8-48 1 2 3 4 5 6 7 8 9 10 11 NOTICE ECB00640 To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. EWB02151 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate.
8-49 1 2 3 4 5 6 7 8 9 10 11 EWB02180 4. Place a new headlight bulb into position. NOTICE ECB00650 Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affect- ed.
8-50 1 2 3 4 5 6 7 8 9 10 11 7. Install the panel. 8. Adjust the headlight beam if necessary. EBU25551 Adjusting a headlight beam NOTICE ECB00690 It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a).
8-51 1 2 3 4 5 6 7 8 9 10 11 Rear 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. EBU25681 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts.
8-52 1 2 3 4 5 6 7 8 9 10 11 EBU25730 Troubleshooting Although Yamaha ATVs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power.
8-53 1 2 3 4 5 6 7 8 9 10 11 EBU27681 Troubleshooting charts Starting problems or poor engine performance 1. Fuel 2. Compression 3. Ignition 4. Battery.
8-54 1 2 3 4 5 6 7 8 9 10 11 Engine overheating EWB02270 TIP If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible. W ARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot.
9-1 1 2 3 4 5 6 7 8 9 10 11 EBU25860 CLEANING AND STORAGE EBU25890 Cleaning Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV: a.
9-2 1 2 3 4 5 6 7 8 9 10 11 EWB02300 EBU27260 Storage Short-term Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover. NOTICE ECB00720 ● Storing the ATV in a poorly ventilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust.
9-3 1 2 3 4 5 6 7 8 9 10 11 the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. 4. Lubricate all control cables and the pivoting points of all levers and pedals.
10-1 1 2 3 4 5 6 7 8 9 10 11 EBU25960 SPECIFICATIONS EBU2597D Dimensions: Overall length: 1795 mm (70.7 in) Overall width: 1240 mm (48.8 in) Overall height: 1065 mm (41.9 in) Seat height: 810 mm (31.9 in) Wheelbase: 1270 mm (50.0 in) Ground clearance: 235 mm (9.
10-2 1 2 3 4 5 6 7 8 9 10 11 Engine oil quantity: Without oil filter element replacement: 1.40 L (1.48 US qt, 1.23 Imp.qt) With oil filter element replacement: 1.45 L (1.53 US qt, 1.28 Imp.qt) Cooling system: Coolant reservoir capacity (up to the maximum level mark): 0.
10-3 1 2 3 4 5 6 7 8 9 10 11 Trail: 21.0 mm (0.83 in) Front tire: Type: Tubeless Size: AT21 x 7R-10 Manufacturer/model: DUNLOP/KT351 Radial Rear tire: Type: Tubeless Size: AT20 x 10R-9 Manufacturer/model: DUNLOP/KT356 Radial Loading: Maximum loading limit: 100.
10-4 1 2 3 4 5 6 7 8 9 10 11 Rear suspension: Type: Swingarm (link suspension) Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 280 mm (11.0 in) Electrical system: Ignition system: TCI (digital) Charging system: AC magneto Battery: Model: YTZ-7S Voltage, capacity: 12 V, 6.
11-1 1 2 3 4 5 6 7 8 9 10 11 EBU25981 CONSUMER INFORMATION EBU26011 Identification numbers Record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a Yamaha dealer or for ref- erence in case the ATV is stolen.
11-2 1 2 3 4 5 6 7 8 9 10 11 TIP The vehicle identification number is used to identi- fy your ATV. EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- er.
11-3 1 2 3 4 5 6 7 8 9 10 11 EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering ino.
11-4 1 2 3 4 5 6 7 8 9 10 11 EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.
11-5 1 2 3 4 5 6 7 8 9 10 11 EBU26501 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY Y amaha Motor Corporation, U.S .A. hereby warr ants that new Y amaha A TVs purchased from an authorized Y am.
11-6 1 2 3 4 5 6 7 8 9 10 11 W ARRANTY QUESTIONS AND ANSWERS Q. What costs are my responsibility during the warranty period? A. The customer ’ s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages , and oil, oil filters, air filters, spark plugs, and brake shoes .
11-7 1 2 3 4 5 6 7 8 9 10 11 EBU26122 YAMAHA EXTENDED SERVICE (Y.E.S.) K eep your Y amaha protected even after y our warranty expires with gen uine Y amaha Extended Service (Y .E.S.). Y .E.S. is designed and administered by Y amaha Motor Corporation to provide maximum owner satisf action.
11-8 1 2 3 4 5 6 7 8 9 10 11 We urge y ou to act now . Y ou ’ ll get the excellent benefits of TRIP cov erage right awa y , and you ’ ll rest easy knowing you ’ ll ha ve strong f actory-backed protection e ven after y our Y amaha Limited W arranty e xpires.
11-9 1 2 3 4 5 6 7 8 9 10 11 EBU26132.
INDEX A Accessories and loading ................................................ 6-6 Air filter element, cleaning ............................................ 8-23 B Battery .......................................................................... 8-45 Brake and clutch levers, checking and lubricating .
L Label locations ................................................................2-1 Light switch .....................................................................4-3 M Main switch .................................................................
PRINTED IN JAP AN 2008.09-4.4x2 ! (E) Y AMAHA MOT OR CO. , L TD. PRINTED ON RECYCLED PAPER LOCATE AND READ OWNER ’ S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) WARNING ALWAYS : use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns.
Dear New Y amaha A TV Owner: CONGRA TULA TIONS ON THE PURCHASE OF YOUR NEW Y AMAHA A TV . Y ou have purchased a quality Y amaha pr oduct that , with proper use and care , will pro vide hours of riding pleasure.
NO POST AGE NECESSARY IF MAILED IN THE UNITED ST A TES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POST AGE WILL BE P AID BY ADDRESSEE Y AMAHA MOTOR CORPORA TION U.
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