READ THIS MANUAL CAREFULLY! It contains important safety information.
U4S110E0.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU17170 INTRODUCTION EBU17270 Congratulations on your purchase of the Yamaha YFM40FBW. This ATV represents the result of many years of 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.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM 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. Please check your local riding laws and regulations before operating this ATV.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EWB00010 WARNING 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 ............................ 2-1 DESCRIPTION .............................................. 3-1 Left view ...................................................... 3-1 Right view....................................................
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM Throttle lever .............................................. 5-4 Tires ........................................................... 5-5 Measuring the tire pressure ....................... 5-6 Tire wear limit ............................................. 5-7 Chassis fasteners ....................................... 5-7 Instruments, lights and switches ................ 5-7 CROSSING THROUGH SHALLOW WATER....................................................
U4S110E0.book Page 3 Friday, August 4, 2006 4:03 PM Checking the front brake pads and rear brake friction plates ......................... 8-27 Checking the brake fluid level .................. 8-28 Changing the brake fluid .......................... 8-29 Checking the front brake lever free play ......................................................... 8-29 Adjusting the brake pedal and rear brake lever free play ............................... 8-30 Axle boots ..............................................
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU17430 SAFETY INFORMATION EBU17442 AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM ● 1 ● ● ● ● 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 this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
U4S110E0.book Page 3 Friday, August 4, 2006 4:03 PM ● ● ● ● 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 uphill. Turn the ATV around and remount, following the procedure described in this manual. Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees.
U4S110E0.book Page 4 Friday, August 4, 2006 4:03 PM EWB00021 WARNING 1 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. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling.
U4S110E0.book Page 5 Friday, August 4, 2006 4:03 PM 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 adequate ventilation.
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U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM 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 replacement label from your Yamaha dealer.
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U4S110E0.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly spring preload adjusting ring 2. Fuel cock 3. Recoil starter 4. Throttle stop screw 5. Fuses 6. Battery 1. 2. 3. 4. 5. 6. 7.
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM EBU17712 Controls and instruments NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual. 3 1. 2. 3. 4. 5. 6. 7. 8.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4 EBU17770 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power. The headlights, meter lighting and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. OFF All electrical systems are off.
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM EBU17813 NOTE: If the indicator light flashes under any other circumstances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. Indicator lights and warning light EBU17870 Neutral indicator light “NEUTRAL” This indicator light comes on when the transmission is in the neutral position. EBU26931 1. 2. 3. 4. 5.
U4S110E0.book Page 3 Friday, August 4, 2006 4:03 PM If the warning light stays on, allow the engine to cool. If the warning light stays on when the engine is cool, have a Yamaha dealer check the electrical circuit. ECB00010 4 CAUTION: ● The engine may overheat if the ATV is overloaded. In this case, reduce the load to specification. ● Start the engine after making sure that the warning light is out. Continuous use while the warning light is on may cause damage to the engine.
U4S110E0.book Page 4 Friday, August 4, 2006 4:03 PM 4 1. 2. 3. 4. Reset knob Speedometer Odometer Tripmeter EBU18050 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank. When the needle reaches the red line, refill the tank at the first opportunity. 1. Fuel gauge 2. Red line NOTE: If the ATV runs out of fuel, move the fuel cock lever to the “RES” position. Approximately 4.0 L (1.06 US gal) (0.88 Imp.gal) of fuel will be remaining in the tank.
U4S110E0.book Page 5 Friday, August 4, 2006 4:03 PM EBU18061 EBU18100 Handlebar switches Start switch “ ” Push this switch to crank the engine with the starter. ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. 4 EBU18160 1. 2. 3. 4. Light switch “ / /OFF” Start switch “ ” Engine stop switch “ / ” Override switch “OVERRIDE” EBU18080 Engine stop switch “ / ” Set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and .
U4S110E0.book Page 6 Friday, August 4, 2006 4:03 PM EBU28350 EWB00110 Override switch “OVERRIDE” 1. Override switch “OVERRIDE” Top speed is normally limited when operating in differential gear lock. If conditions require more engine power when riding forward, push and hold this switch to override the differential gear lock speed limiting function. (See page 4-8.) Releasing the switch restores the speed limiting function. While the override switch is pushed, the reverse in.
U4S110E0.book Page 7 Friday, August 4, 2006 4:03 PM ● 4 “4WD” (four-wheel drive): Power is supplied to the rear and front wheels. To change from two-wheel drive to four-wheel drive, stop the ATV and push the switch in to the “4WD” position. The four-wheel-drive indicator light “ ” comes on. To change from four-wheel drive to two-wheel drive, stop the ATV and push the switch in to the “2WD” position. 1.
U4S110E0.book Page 8 Friday, August 4, 2006 4:03 PM EBU28360 On-Command differential gear lock switch “4WD”/“LOCK” This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive. Select the appropriate switch position according to the terrain and the conditions. ● “4WD” (four-wheel drive): Power is supplied to the rear and front wheels.
U4S110E0.book Page 9 Friday, August 4, 2006 4:03 PM 4 1. On-Command differential gear lock switch “4WD”/“LOCK” To release the differential gear lock, stop the ATV and push the switch to the “4WD” position. WHAT CAN HAPPEN The ATV handles differently in four-wheel drive than in differential gear lock in some circumstances. Changing from four-wheel drive to differential gear lock or vice-versa while moving may cause the ATV to handle differently unexpectedly.
U4S110E0.book Page 10 Friday, August 4, 2006 4:03 PM HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in differential gear lock, and allow extra time and distance for maneuvers. NOTE: ● If the differential gear lock is not engaging properly, turn the handlebar back and forth to help it engage. ● Riding before the differential gear lock is properly engaged will cause the engine speed to be limited until engagement is complete.
U4S110E0.book Page 11 Friday, August 4, 2006 4:03 PM EWB00200 WARNING 4 POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV.
U4S110E0.book Page 12 Friday, August 4, 2006 4:03 PM WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. 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 8-26.) EBU18391 Front brake lever The front brake lever is located on the right handlebar.
U4S110E0.book Page 13 Friday, August 4, 2006 4:03 PM EBU18450 Parking brake Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. 4 1. Brake pedal 1.
U4S110E0.book Page 14 Friday, August 4, 2006 4:03 PM WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely. HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine.
U4S110E0.book Page 15 Friday, August 4, 2006 4:03 PM 4 1. Reverse knob “REV” 1. Recoil starter EWB02361 EBU27371 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out. WARNING POTENTIAL HAZARD Starting the engine in gear or starting the engine without applying the parking brake. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident.
U4S110E0.book Page 16 Friday, August 4, 2006 4:03 PM EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 4 1. Fuel level 2. Fuel tank filler tube 1. Fuel tank cap EBU18730 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 15.0 L (3.96 US gal) (3.30 Imp.gal) Fuel reserve amount: 4.0 L (1.06 US gal) (0.88 Imp.
U4S110E0.book Page 17 Friday, August 4, 2006 4:03 PM ECB00070 CAUTION: 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 Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.
U4S110E0.book Page 18 Friday, August 4, 2006 4:03 PM OFF ON 4 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding.
U4S110E0.book Page 19 Friday, August 4, 2006 4:03 PM RES 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. 4 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding.
U4S110E0.book Page 20 Friday, August 4, 2006 4:03 PM 4 1. Seat lock lever 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. NOTE: Make sure that the seat is securely fitted. 1. Seat holder 2. Projection EBU18901 Storage compartment ECB00130 CAUTION: Do not store metal or sharply edged objects, like tools, in the storage compartment.
U4S110E0.book Page 21 Friday, August 4, 2006 4:03 PM EBU18970 Rear carrier ● ● Do not exceed the load limit of 80.0 kg (176 lb) for the rear carrier. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. EBU19130 Adjusting the front and rear shock absorber assemblies 4 1. Storage compartment ● ● Do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV.
U4S110E0.book Page 22 Friday, August 4, 2006 4:03 PM 4 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. 1.
U4S110E0.book Page 23 Friday, August 4, 2006 4:03 PM EWB00350 WARNING 4 POTENTIAL HAZARD Improper shock absorber assembly adjustment. 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 assemblies on the left and right side to the same setting. EBU19180 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV.
U4S110E0.book Page 24 Friday, August 4, 2006 4:03 PM ● ● If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult. Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU19200 PRE-OPERATION CHECKS EBU19210 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. 5 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.
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM ITEM Throttle lever Control cables Wheels and tires Brake and shift pedals Brake levers Axle boots Chassis fasteners Instruments, lights and switches ROUTINE • Make sure that operation is smooth. Lubricate cable and lever housing if necessary. • Check cable free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate if necessary. • Check wheel condition, and replace if damaged. • Check tire condition and tread depth.
U4S110E0.book Page 3 Friday, August 4, 2006 4:03 PM EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. (See page 4-16.) Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-15.) EWB00500 WARNING 5 POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up.
U4S110E0.book Page 4 Friday, August 4, 2006 4:03 PM Brake fluid level (front brake) Check the brake fluid level. Add fluid if necessary. (See page 8-28.) Recommended brake fluid: DOT 4 Brake fluid leakage (front brake) Check to see if any brake fluid is leaking out of the hose, joint or brake fluid reservoir of the front brake. Apply the brake firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system.
U4S110E0.book Page 5 Friday, August 4, 2006 4:03 PM EBU19801 Tires EWB00551 WARNING 5 POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD ● The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model.
U4S110E0.book Page 6 Friday, August 4, 2006 4:03 PM ● ● ● Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (36 psi) (2.5 kgf/cm²) Rear: 250 kPa (36 psi) (2.
U4S110E0.book Page 7 Friday, August 4, 2006 4:03 PM 5 Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Rear 28.0 kPa (4.1 psi) (0.280 kgf/cm²) 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU19870 OPERATION EWB00010 EBU19981 WARNING Indicates a potential hazard that could result in serious injury or death. EBU19890 EWB00610 WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM 4. Shift the transmission into neutral. The neutral indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. Ambient temp./starter (choke) position NOTE: The engine can be started under the following conditions: ● The transmission is in neutral. ● The rear brake lever is applied with the transmission in any gear.
U4S110E0.book Page 3 Friday, August 4, 2006 4:03 PM ● If the battery is discharged, pull the recoil starter to start the engine. 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine. If the engine is started with the starter (choke) in position (2), keep the starter (choke) in this position to warm up the engine. ECB00160 CAUTION: For maximum engine life, always warm the engine up before starting off.
U4S110E0.book Page 4 Friday, August 4, 2006 4:03 PM EWB00660 WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or even a person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no people or obstacles behind you. When it is safe to proceed, go slowly. 6 1. Reverse knob “REV” 2. Shift pedal EBU20540 Shifting NOTE: When in reverse, the reverse indicator light should come on.
U4S110E0.book Page 5 Friday, August 4, 2006 4:03 PM 5. Shift into second gear and release the shift pedal. 6. Open the throttle gradually. 7. Follow the same procedure when shifting to the next higher gear. EWB00690 WARNING 1. Shift pedal 2. Neutral position 3. Reverse position EBU20600 To start out and accelerate 1. Release the throttle lever. POTENTIAL HAZARD Opening the throttle before releasing the shift pedal. WHAT CAN HAPPEN The ATV could wheelie.
U4S110E0.book Page 6 Friday, August 4, 2006 4:03 PM EWB00650 EBU20672 WARNING 6 POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating and lose traction. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear.
U4S110E0.book Page 7 Friday, August 4, 2006 4:03 PM 160–320 km (100–200 mi) or 10–20 hours Avoid prolonged operation above 3/4 throttle. Rev the engine through the gears freely, but do not use full throttle at any time. 320 km (200 mi) or 20 hours and beyond The ATV can now be operated normally. ECB00220 CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV.
U4S110E0.book Page 8 Friday, August 4, 2006 4:03 PM EBU20830 Parking on a slope EWB00790 WARNING 6 POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines.
U4S110E0.book Page 9 Friday, August 4, 2006 4:03 PM ● ● ● ity or suitability. Choose a genuine Yamaha accessory, 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. Do not mount an accessory where it could interfere with your ability to control the ATV.
U4S110E0.book Page 10 Friday, August 4, 2006 4:03 PM ● ● ● ● 6 ● ● ● Load cargo on the carriers as close to the center of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. Make sure the load does not interfere with controls or your ability to see where you are going.
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U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. ular attention to the safety information on pages 1-1–1-5. Please also read all caution and warning labels on your ATV. RIDE WITH CARE AND GOOD JUDGEMENT EBU28450 7 GETTING TO KNOW YOUR ATV This ATV is mainly for utility use, but may also be used for recreation. This section, Riding your ATV, provides general ATV riding instructions for recreational riding.
U4S110E0.book Page 3 Friday, August 4, 2006 4:03 PM HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-8872887. Riding your ATV requires skills acquired through practice over a period of time.
U4S110E0.book Page 4 Friday, August 4, 2006 4:03 PM This ATV is designed to carry operator and cargo only – passengers prohibited. EWB00910 WARNING 7 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 passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation.
U4S110E0.book Page 5 Friday, August 4, 2006 4:03 PM Apparel EWB00920 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.
U4S110E0.book Page 6 Friday, August 4, 2006 4:03 PM Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. 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.
U4S110E0.book Page 7 Friday, August 4, 2006 4:03 PM EWB00950 WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner’s Manual for this ATV on page 5-5.
U4S110E0.book Page 8 Friday, August 4, 2006 4:03 PM Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-11.
U4S110E0.book Page 9 Friday, August 4, 2006 4:03 PM 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. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
U4S110E0.book Page 10 Friday, August 4, 2006 4:03 PM During operation Always keep your feet on the footboards during operation, otherwise they may contact the rear wheels. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
U4S110E0.book Page 11 Friday, August 4, 2006 4:03 PM HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. Modifications EWB01000 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
U4S110E0.book Page 12 Friday, August 4, 2006 4:03 PM 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 7 POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire.
U4S110E0.book Page 13 Friday, August 4, 2006 4:03 PM HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. EWB01030 WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
U4S110E0.book Page 14 Friday, August 4, 2006 4:03 PM 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 7 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.
U4S110E0.book Page 15 Friday, August 4, 2006 4:03 PM HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. 7 EWB01060 WARNING When riding in an area where you might not easily mount a caution POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles.
U4S110E0.book Page 16 Friday, August 4, 2006 4:03 PM Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. 7 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. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.
U4S110E0.book Page 17 Friday, August 4, 2006 4:03 PM When slowing down or stopping, release the throttle 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 control and increasing the possibility of an accident. EWB01070 WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high.
U4S110E0.book Page 18 Friday, August 4, 2006 4:03 PM TURNING YOUR ATV To achieve maximum traction while riding off-road in 2WD or 4WD, the two rear wheels turn together at the same speed. Furthermore, when riding in 4WD-LOCK (“DIFF. LOCK”), the front wheels also turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning.
U4S110E0.book Page 19 Friday, August 4, 2006 4:03 PM Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over.
U4S110E0.book Page 20 Friday, August 4, 2006 4:03 PM CLIMBING UPHILL Use proper riding techniques to avoid ATV overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
U4S110E0.book Page 21 Friday, August 4, 2006 4:03 PM 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. EWB01190 WARNING WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
U4S110E0.book Page 22 Friday, August 4, 2006 4:03 PM could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediately on the uphill side. EWB02420 WARNING 7 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 uphill side.
U4S110E0.book Page 23 Friday, August 4, 2006 4:03 PM If you begin rolling backwards: ● Keep weight uphill. ● 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. When fully stopped, apply the rear brake as well, and then lock the parking brake. ● 4WD or 4WD-LOCK: Apply both front and rear brakes gradually. When fully stopped, lock the parking brake. Dismount on uphill side or to a side if pointed straight uphill.
U4S110E0.book Page 24 Friday, August 4, 2006 4:03 PM 7 RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, change to 4WD or 4WD-LOCK before beginning to descend the hill and choose a low gear which will allow the engine compression to do most of the braking for you.
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U4S110E0.book Page 26 Friday, August 4, 2006 4:03 PM 7 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. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. As you travel across a slope, lean your body in the uphill direction.
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U4S110E0.book Page 28 Friday, August 4, 2006 4:03 PM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow 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. Drive slowly and carefully. EWB01150 WARNING 7 POTENTIAL HAZARD Operating this ATV through deep or fast flowing water.
U4S110E0.book Page 29 Friday, August 4, 2006 4:03 PM 1. Air filter case check hose ECB00240 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. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions.
U4S110E0.book Page 30 Friday, August 4, 2006 4:03 PM RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide.
U4S110E0.book Page 31 Friday, August 4, 2006 4:03 PM WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
U4S110E0.book Page 32 Friday, August 4, 2006 4:03 PM ● ● ● 7 ● If your ATV begins to tip while turning: Lean more into the turn to regain balance. If necessary, gradually let off the throttle and/or steer to the outside of the turn. (See page 7-18.) If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See page 7-30.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU21642 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21660 Safety is an obligation of the owner. Periodic inspection, 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.
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM EWB01830 WARNING 1. Owner’s tool kit 2. Low-pressure tire gauge 8 The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. POTENTIAL HAZARD Operating this ATV with improper modifications.
U4S110E0.book Page 3 Friday, August 4, 2006 4:03 PM EBU21742 Periodic maintenance chart for the emission control system NOTE: ● 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 intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
U4S110E0.book Page 4 Friday, August 4, 2006 4:03 PM INITIAL NO. 6 7 8 * ITEM Exhaust system Spark arrester CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Check for leakage and replace gasket(s) if necessary. • Check for looseness and tighten all screw clamps and joints if necessary. • Clean.
U4S110E0.book Page 5 Friday, August 4, 2006 4:03 PM EBU21863 General maintenance and lubrication chart INITIAL NO. 1 ITEM 3 * Front brake 6 * * 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Check operation and adjust if necessary. • Check operation and correct if necessary. • Check fluid level and ATV for fluid leakage, and correct if necessary. • Replace brake pads. • Check operation and correct if necessary. • Check brake lever and pedal free play, and adjust if necessary.
U4S110E0.book Page 6 Friday, August 4, 2006 4:03 PM INITIAL NO. 8 ITEM 9 * Drive shaft universal joint 10 * Chassis fasteners 11 * Shock absorber assemblies 12 * Stabilizer bushes 13 14 * * Knuckle pivots Steering shaft 15 * Steering system 16 * Axle boots 17 18 Engine oil Engine oil filter ele- CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Lubricate with lithium-soap-based grease.
U4S110E0.book Page 7 Friday, October 20, 2006 10:10 AM INITIAL NO. 21 ITEM Final gear oil Moving parts and cables Reverse lock release cable 22 * 23 * 24 * Throttle lever housing and cable 25 * Front and rear brake switches 26 * Lights and switches EBU28390 CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Change. • Check ATV for oil leakage, and correct if necessary. √ √ • Lubricate.
U4S110E0.book Page 8 Friday, August 4, 2006 4:03 PM • Every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.
U4S110E0.book Page 9 Friday, August 4, 2006 4:03 PM EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23211 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 accordance with the periodic maintenance and lubrication chart.
U4S110E0.book Page 10 Friday, August 4, 2006 4:03 PM Specified spark plug: NGK/DR8EA To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) 1. Spark plug wrench 8 To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the ATV is ridden normally).
U4S110E0.book Page 11 Friday, August 4, 2006 4:03 PM 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) 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. 2. Check the engine oil level on a cold engine.
U4S110E0.book Page 12 Friday, August 4, 2006 4:03 PM To change the engine oil (with or without oil filter element cleaning) 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase. 1. Dipstick 2. Maximum level mark 3.
U4S110E0.book Page 13 Friday, August 4, 2006 4:03 PM ECB00310 CAUTION: When removing the engine oil drain bolt, the compression spring, oil strainer and O-ring will fall out. Take care not to lose these parts. NOTE: Skip steps 5–9 if the oil filter element is not being cleaned. 5. Remove the oil filter element cover by removing the bolts, and then remove the oil filter element. 1. O-ring 2. Oil filter element 6. Clean the oil strainer and oil filter element with solvent. 7.
U4S110E0.book Page 14 Friday, August 4, 2006 4:03 PM Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 10. Install the oil strainer, compression spring, Oring and engine oil drain bolt. Tighten the engine oil drain bolt to the specified torque. Recommended oil: See page 10-1. Oil quantity: Without oil filter element replacement: 2.90 L (3.07 US qt) (2.55 Imp.qt) With oil filter element replacement: 3.00 L (3.17 US qt) (2.64 Imp.
U4S110E0.book Page 15 Friday, August 4, 2006 4:03 PM EBU28560 Final gear oil The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the final gear oil level 1. Place the ATV on a level surface.
U4S110E0.book Page 16 Friday, August 4, 2006 4:03 PM To change the final gear oil 1. Remove the final gear case guard by removing the bolts. 1. Final gear oil drain bolt 8 1. Final gear case guard 2. Bolt 2. Place the ATV on a level surface. 3. Place an oil pan under the final gear case to collect the used oil. 4. Remove the final gear oil filler bolt and the final gear oil drain bolt to drain the oil from the 5. Install the drain bolt, and then tighten it to the specified torque.
U4S110E0.book Page 17 Friday, August 4, 2006 4:03 PM ECB00420 CAUTION: Be sure no foreign material enters the final gear case. 7. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 1. Final gear oil filler bolt 2. Correct oil level 3. Final gear oil Recommended final gear oil: See page 10-1. NOTE: If the recommended oil is not available, SAE80W90 API GL-5 Hypoid gear oil may be used instead.
U4S110E0.book Page 18 Friday, August 4, 2006 4:03 PM In addition, the differential gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the differential gear oil level 1. Place the ATV on a level surface. NOTE: The differential gear oil level must be checked on a cold engine. 2. Remove the differential gear oil filler bolt, and then check the oil level in the differential gear case. 8 1.
U4S110E0.book Page 19 Friday, August 4, 2006 4:03 PM To change the differential gear oil 1. Place the ATV on a level surface. 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. 5. Add the recommended differential gear oil to the brim of the filler hole as shown. 1. Differential gear oil 2. Differential gear oil filler bolt 3.
U4S110E0.book Page 20 Friday, August 4, 2006 4:03 PM Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7. Check the differential gear case for oil leakage. If oil is leaking, check for the cause. EBU23671 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas.
U4S110E0.book Page 21 Friday, August 4, 2006 4:03 PM 1. Air filter case cover 2. Air filter case cover holder 3. Pull the air filter element assembly out of the air filter case. 1. Air filter element assembly 4. Remove the sponge material from the air filter element.
U4S110E0.book Page 22 Friday, August 4, 2006 4:03 PM 6. Squeeze the excess water or solvent out of the sponge material and let it dry. ECB00470 CAUTION: ● Do not twist the sponge material when squeezing it. ● Do not apply oil to the sponge material. 7. Check the sponge material and replace it if damaged. 8. Tap the air filter element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown. If the air filter element is damaged, replace it. 1.
U4S110E0.book Page 23 Friday, August 4, 2006 4:03 PM 9. Pull the sponge material over the air filter element. 10. Insert the air filter element assembly into the air filter case, and then install the air filter case cover by hooking the holders onto the air filter case. 11. Install the seat. NOTE: The air filter element should be cleaned every 20– 40 hours. It should be cleaned more often if the ATV is operated in extremely dusty areas.
U4S110E0.book Page 24 Friday, August 4, 2006 4:03 PM 2. Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel. 3. Stop the engine and allow the exhaust pipe to cool. 4. Install the purging bolt, and then tighten it to the specified torque. Tightening torque: Purging bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) EWB01920 WARNING 8 POTENTIAL HAZARD Improperly purging the exhaust system.
U4S110E0.book Page 25 Friday, August 4, 2006 4:03 PM ECB00480 CAUTION: The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine. crease the engine idling speed, turn the throttle stop screw in direction (a), and to decrease it, turn the screw in direction (b).
U4S110E0.book Page 26 Friday, August 4, 2006 4:03 PM EBU24043 Adjusting the throttle cable free play The throttle cable free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The throttle cable free play should measure 3.0– 5.0 mm (0.12–0.20 in) at the throttle lever. Periodically check the throttle cable free play and, if necessary, adjust it as follows.
U4S110E0.book Page 27 Friday, August 4, 2006 4:03 PM EBU24080 EBU24171 Adjusting the reverse lock release cable Front brake pads Check each front brake pad for damage and measure the lining thickness. If a brake pad is damaged or if the lining thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the brake pads as a set. The reverse lock release cable stretches with use, which can result in improper function.
U4S110E0.book Page 28 Friday, August 4, 2006 4:03 PM 8 EBU28421 EBU24251 Rear brake friction plates The rear brake is provided with a wear indicator, which allows you to check the brake friction plate wear without having to disassemble the brake. To check the brake friction plate wear, check the position of the wear indicator while applying the brake.
U4S110E0.book Page 29 Friday, August 4, 2006 4:03 PM ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 ● ● ● ● 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.
U4S110E0.book Page 30 Wednesday, October 11, 2006 11:38 AM EWB02010 WARNING 8 POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. ● Make sure the brakes are not spongy. All air must be bled from the brake system.
U4S110E0.book Page 31 Wednesday, October 11, 2006 11:38 AM 1. Brake lever free play 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 1. Locknut 2. Brake lever free play adjusting bolt 2. Fully loosen the brake lever free play adjusting nut on the brake cable at the final gear case.
U4S110E0.book Page 32 Wednesday, October 11, 2006 11:38 AM 1. Brake lever free play adjusting nut 8 3. Push the brake camshaft lever in direction (a) until it stops [apply approximately 47 N (10.6 lbf) (4.8 kgf) of force], and then turn the brake pedal free play adjusting nut on the brake cable at the final gear case so that gap “A” measures 2.5–3.0 mm (0.10–0.12 in). 1. Brake pedal free play adjusting nut 2. Brake camshaft lever 3. Gap “A” 4.
U4S110E0.book Page 33 Wednesday, October 11, 2006 11:38 AM 1. Brake lever free play adjusting nut 2. Brake camshaft lever 3. Gap “B” 5. Check the brake lever free play and, if necessary, adjust it by turning the brake lever free play adjusting bolt at the brake lever. Turn the brake lever free play adjusting bolt in direction (a) to increase the free play, and in direction (b) to decrease it. 1. Locknut 2. Brake lever free play adjusting bolt 6. Tighten the locknut at the brake lever.
U4S110E0.book Page 34 Wednesday, October 11, 2006 11:38 AM EWB02020 WARNING 8 POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.
U4S110E0.book Page 35 Friday, August 4, 2006 4:03 PM EBU24740 Brake light switches The operation of the brake light switches must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication 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. NOTE: The brake light switch is properly adjusted when the brake light comes on just before braking takes effect.
U4S110E0.book Page 36 Friday, August 4, 2006 4:03 PM NOTE: When tightening the locknut, hold the adjusting bolt with a screwdriver so that the adjusting bolt does not turn together with the locknut. EBU24890 Checking and lubricating the cables 1. Locknut 2. Adjusting bolt 8 NOTE: Turning the adjusting bolt out decreases clutch free play and turning it in increases clutch free play. 3. Tighten the locknut to the specified torque.
U4S110E0.book Page 37 Friday, August 4, 2006 4:03 PM WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables.
U4S110E0.book Page 38 Friday, August 4, 2006 4:03 PM EBU24930 Checking and lubricating the brake and shift pedals Shift pedal The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
U4S110E0.book Page 39 Friday, August 4, 2006 4:03 PM Recommended lubricant: Lithium-soap-based grease EBU25021 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 bushes if necessary. EBU25050 1.
U4S110E0.book Page 40 Friday, August 4, 2006 4:03 PM EBU25212 Battery This model is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections. ECB00620 CAUTION: Never attempt to remove the battery cell seals, as this would permanently damage the battery.
U4S110E0.book Page 41 Friday, August 4, 2006 4:03 PM 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. To install the battery NOTE: Be sure the battery is fully charged. 1. Place the battery in its compartment. 2. Make sure to properly connect the battery leads to the battery terminals. ECB00630 CAUTION: ● Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.
U4S110E0.book Page 42 Friday, August 4, 2006 4:03 PM EBU25313 Replacing a fuse 8 1. 2. 3. 4. 5. Main fuse Spare main fuse Spare fuse Four-wheel-drive motor fuse Fuse box 1. 2. 3. 4. 5. Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse Spare fuse The main fuse and the fuse box are located under the seat. (See page 4-19.) If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off all electrical circuits.
U4S110E0.book Page 43 Friday, August 4, 2006 4:03 PM 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Ignition fuse: 15.0 A Four-wheel-drive motor fuse: 10.0 A Auxiliary DC jack fuse: 10.0 A Carburetor warmer fuse: 10.0 A EWB02151 WARNING POTENTIAL HAZARD Using an improper fuse. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse. 3.
U4S110E0.book Page 44 Friday, August 4, 2006 4:03 PM 1. Coupler 2. Screw 8 3. Remove the headlight unit from the headlight assembly by removing the headlight beam adjusting screw and headlight unit screws. 1. Headlight beam adjusting screw 2. Headlight unit screw 4. Remove the headlight bulb holder cover by pulling it off.
U4S110E0.book Page 45 Friday, August 4, 2006 4:03 PM 6. Remove the defective bulb by pulling it out. EWB02180 WARNING 1. Headlight bulb holder cover 5. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable.
U4S110E0.book Page 46 Friday, August 4, 2006 4:03 PM ECB00670 CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 1. Do not touch the glass part of the bulb. 10. Place the headlight unit in the original position, and then install the screws. 11. Place the headlight assembly in the original position, and then install the screws. 12. Connect the coupler which was disconnected in step “1”. 13. Adjust the headlight beam. (See page 8-46.
U4S110E0.book Page 47 Friday, August 4, 2006 4:03 PM 1. Headlight beam adjusting screw 1. Storage compartment 2. Nut EBU25631 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Open the storage compartment. (See page 4-20.) 2. Remove the tail/brake light assembly by removing the nuts together with the washers. 3. Remove the bulb holder (together with the bulb) by turning it counterclockwise.
U4S110E0.book Page 48 Friday, August 4, 2006 4:03 PM 1. Tail/brake light bulb holder 2. Tail/brake light assembly 8 4. Remove the defective bulb by pushing it in and turning it counterclockwise. 1. Tail/brake light bulb holder 2. Tail/brake light bulb 5. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 6. Install the bulb holder (together with the bulb) by turning it clockwise. 7. Install the tail/brake light assembly by installing the washers and the nuts.
U4S110E0.book Page 49 Friday, August 4, 2006 4:03 PM ● Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Wheel nut 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. EBU25700 Installing a wheel 1. Install the wheel and the nuts. NOTE: ust point toward 1.
U4S110E0.book Page 50 Friday, August 4, 2006 4:03 PM EBU25710 Troubleshooting 1. Tapered nut 8 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) Although Yamaha ATVs receive a thorough inspection before shipment from the factory, trouble may occur during operation.
U4S110E0.book Page 51 Friday, August 4, 2006 4:03 PM HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.
U4S110E0.book Page 52 Friday, August 4, 2006 4:03 PM EBU25751 Troubleshooting chart 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the ATV. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 3.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU25860 CLEANING AND STORAGE EBU25870 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. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. b. Make sure the spark plug and all filler caps are properly installed. 2.
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM ● EWB02300 WARNING POTENTIAL HAZARD Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping ability, increasing the chance of an accident. HOW TO AVOID THE HAZARD Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. EBU25932 Storage 9 Short-term Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover.
U4S110E0.book Page 3 Friday, August 4, 2006 4:03 PM b. Pour a teaspoonful of engine oil into the spark plug bore. c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with 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. 6.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU25960 SPECIFICATIONS Dimensions: Overall length: 2016 mm (79.4 in) Overall width: 1116 mm (43.9 in) Overall height: 1187 mm (46.7 in) Seat height: 895 mm (35.2 in) Wheelbase: 1230 mm (48.4 in) Ground clearance: 267 mm (10.5 in) Minimum turning radius: 3200 mm (126 in) Compression ratio: 8.
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM With oil filter element replacement: 3.00 L (3.17 US qt) (2.64 Imp.qt) Final gear oil: Type: Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: ACC-SHAFT-LU-00) Quantity: 0.50 L (0.53 US qt) (0.44 Imp.qt) Differential gear oil: Type: Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: ACC-SHAFT-LU-00) or SAE80 API GL-4 Hypoid gear oil Quantity: 0.23 L (0.24 US qt) (0.20 Imp.
U4S110E0.book Page 3 Friday, August 4, 2006 4:03 PM Reverse gear: 22/17 × 35/15 (3.020) Chassis: Frame type: Steel tube frame Caster angle: 3.0 ° Trail: 17.0 mm (0.67 in) Front tire: Type: Tubeless Size: AT25 x 8-12 Manufacturer/model: ITP/MUD LITE Rear tire: 10 Type: Tubeless Size: AT25 x 10-12 Manufacturer/model: ITP/MUD LITE Loading: Maximum loading limit: Rear: 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear: 22.0 kPa (3.2 psi) (0.
U4S110E0.book Page 4 Friday, August 4, 2006 4:03 PM Rear brake: Type: Wet multiple disc brake Operation: Left hand and right foot operation Front suspension: Type: Double wishbone Spring/shock absorber type: Coil spring/oil damper Wheel travel: 147 mm (5.8 in) Rear suspension: Type: Double wishbone Spring/shock absorber type: Coil spring/oil damper Wheel travel: 192 mm (7.6 in) Electrical system: Ignition system: DC.
U4S110E0.book Page 5 Friday, August 4, 2006 4:03 PM Four-wheel-drive motor fuse: 10.
U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM EBU25981 CONSUMER INFORMATION EBU26011 EBU26020 Identification numbers Key identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key.
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM 1. Vehicle identification number (front left side) NOTE: The vehicle identification number is used to identify your ATV. EBU26050 Model label The model label is affixed at the location in the illustration. Record the information on this label in on will be need- 1.
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U4S110E0.book Page 4 Friday, August 4, 2006 4:03 PM EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
U4S110E0.book Page 5 Friday, August 4, 2006 4:03 PM EBU26501 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations. THE PERIOD OF WARRANTY for Yamaha ATVs shall be six (6) months from the date of purchase.
U4S110E0.book Page 6 Friday, August 4, 2006 4:03 PM WARRANTY 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. Q. What are some examples of “abnormal” strain, neglect, or abuse? A. These terms are general and overlap each other in areas.
U4S110E0.book Page 7 Friday, August 4, 2006 4:03 PM EBU26122 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Ser vice (Y.E.S.). Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factor y-backed coverage for extra peace of mind. Y. E. S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, or 36 months beyond your warranty period. Y.E.
U4S110E0.book Page 8 Friday, August 4, 2006 4:03 PM We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: 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).
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U4S110E0.book Page 1 Friday, August 4, 2006 4:03 PM INDEX A Accessories and loading ................................................ 6-8 Accessories, auxiliary jack ........................................... 4-23 Air filter element, cleaning ............................................ 8-20 Axle boots .................................................................... 8-34 D Differential gear lock indicator light ................................ 4-3 Differential gear oil ................................
U4S110E0.book Page 2 Friday, August 4, 2006 4:03 PM K Key identification number ............................................. 11-1 Knuckle pivots, lubricating ........................................... 8-39 Reverse lock release cable, adjusting ......................... 8-27 Riding your ATV ............................................................. 7-1 S L Safety information .......................................................... 1-1 Seat .........................................................
U4S110E0.book Page 3 Friday, August 4, 2006 4:03 PM W Warranty, extended ...................................................... 11-7 Warranty, limited .......................................................... 11-5 Wheel bearings, checking ............................................ 8-38 Wheel, installing ........................................................... 8-49 Wheel, removing ..........................................................
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EBU26151 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER operate: NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.
