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  4. GRIZZLY 450 YFM450DF
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Yamaha GRIZZLY 450 YFM450DF Owner's Manual

Summary of GRIZZLY 450 YFM450DF

  • Page 1

    Dic183 yfm450df yfm450pf/yfm450phf owner’s manual manuel du propriÉtaire manual del propietario 2lc-f8199-61 read this manual carefully! It contains important safety information. Lire attentivement ce manuel! Il comprend d’importantes informations de sécurité. ¡lea este manual atentamente! Contiene ...

  • Page 2

    Dic183 original instructions notice originale manual original printed in usa 2014.02-0.5×1 cr (e,f,s).

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Warning owner’s manual yfm450df yfm450pf/yfm450phf this atv should not be ridden by anyone under 16 years of age. 2lc-f8199-61-e0 u2lc61e0.Book page 1 wednesday, february 26, 2014 3:56 pm.

  • Page 4

    Ebu30096 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. En15997, ansi/svia 1-2010 general manager rv engineering division recreational vehicle business unit business development operations yamaha motor co., ltd. 20 january, 2014 y...

  • Page 5

    En15997, ansi/svia 1-2010 general manager rv engineering division recreational vehicle business unit business development operations yamaha motor co., ltd. 20 january, 2014 yfm450fwad (yfm450pf) (5y4aj47w0e0503801–) (yfm450phf) (5y4aj48w0e0500601–) we, yamaha motor co., ltd. 2500 shingai, iwata, jap...

  • Page 6

    Ebu17171 introduction ebu17293 congratulations on your purchase of the yamaha yfm450df/yfm450pf/yfm450phf. This atv repre- sents 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...

  • Page 7

    Ebu17331 important manual information ebu17343 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 no...

  • Page 8

    Ebu17351 important notice ebu17373 this atv is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this atv on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations before operating this atv. Ebu17411 yfm450df/yfm...

  • Page 9

    Ebu17421 table of contents location of the warning and specification labels .............................. 1-1 safety information ................................ 2-1 description................................................ 3-1 left view...................................................... 3-1 r...

  • Page 10

    Starting a warm engine ............................... 6-3 operating the drive select lever and driving in reverse....................................... 6-3 engine break-in ........................................... 6-5 parking ........................................................ 6-5 parking o...

  • Page 11

    Adjusting the rear brake lever and brake pedal free play, and the brake pedal height ...................................................... 8-41 axle boots ................................................. 8-46 brake light switches .................................. 8-47 checking and lubricating the...

  • Page 12

    1-1 1 ebu29681 location of the warning and specification labels ebu30292 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 re...

  • Page 13

    1-2 1 37s-f817r-00 40 kg ( 88 lbs) 25.0 kpa 0.25 kgf/cm² 3.6 psi 25.0 kpa 0.25 kgf/cm² 3.6 psi 5fu-f816m-m0 1p0-f816p-20 37s-f817r-10 80 kg ( 176 lbs) 5880 n 600 kgf 1322 lbf 147 n 15 kgf 33 lbf 37s-f817s-00 1 3 2 4 5 u2lc61e0.Book page 2 wednesday, february 26, 2014 3:56 pm.

  • Page 14

    1-3 1 1p0-f816r-00 yamaha 1hp-f811r-00 6 7 8 u2lc61e0.Book page 3 wednesday, february 26, 2014 3:56 pm.

  • Page 15

    1-4 1 37s-f816n-00 0.5 kg ( 1 lb ) 37s-f816s-00 yamaha motor co., ltd. 2500 shingai, iwata, japan yfm450fwad 19.4 kw 282 kg 2014 2lc-f155a-00 yamaha motor co., ltd. 2500 shingai, iwata, japan yfm450fwa 19.4 kw 276 kg 2014 1cu-f155a-60 9 10 11 yfm450pf yfm450phf 11 yfm450df u2lc61e0.Book page 4 wedne...

  • Page 16

    1-5 1 familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the owner’s manual. Always use an approved helmet and protective gear. For atv type 1 category y12, use from 12 years old. Operation of this a...

  • Page 17

    1-6 1 **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi this pictogram shows trailer hitch tow weight limit. (combined weight of the trailer and all cargo in the trailer.) overloading can cause loss of control. Loss of control can result in severe injury or death. This unit contains high-p...

  • Page 18

    1-7 1 yamaha motor co., ltd. 2500 shingai, iwata, japan ****** *** kw *** kg **** 1 2 3 4 1 2 3 4 year of construction model name max. Power mass in running order u2lc61e0.Book page 7 wednesday, february 26, 2014 3:56 pm.

  • Page 19

    1-8 1 for oceania 6 1 2 3 4 5 7 8 9 u2lc61e0.Book page 8 wednesday, february 26, 2014 3:56 pm.

  • Page 20

    1-9 1 5880 n 1322 ( 6 0 0 k g f ) ( 1 5 k g f ) 37s-f151k-00 5fu-f816m-20 25 kpa, (3.6 psi) 25 kpa, (3.6 psi) 22 kpa, (3.2 psi) 22 kpa, (3.2 psi) 1 3 4 5 2 u2lc61e0.Book page 9 wednesday, february 26, 2014 3:56 pm.

  • Page 21

    1-10 1 16 under 1p0-f816l-00 7 6 u2lc61e0.Book page 10 wednesday, february 26, 2014 3:56 pm.

  • Page 22

    1-11 1 warning fuel vapors can be a fire or explosion hazard. To avoid injury or death, never store fuel or flammable liquids in this storage compartment. Storage should not exceed 1 lb (0.5 kg) 37s-f151f-00 8 9 u2lc61e0.Book page 11 wednesday, february 26, 2014 3:56 pm.

  • Page 23

    2-1 2 ebu17432 safety information safety information ebu17506 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. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding...

  • Page 24

    2-2 2  never operate at speeds too fast for your skills or the riding conditions. Always go at a speed 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...

  • Page 25

    2-3 2 technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.  always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall- ing, use the proper gear range and maintain a steady speed when climbing a hill. If you s...

  • Page 26

    2-4 2  never maintain an atv without proper knowl- edge. Contact an authorized atv dealer to in- form you on basic atv maintenance. Certain maintenance can only be carried out by certified staff. In the event of an accident 1. If serious injuries are incurred, you may be safer staying next to your ...

  • Page 27

    2-5 2 ungrounded or broken wiring. Visually check for broken wiring and leaking fuel. Leaking fuel can be confirmed by the odor of gasoline. 4. Once immediate safety hazards are con- firmed not to exist, you may remove your hel- met to more closely inspect your vehicle. Check for external signs of w...

  • Page 28

    2-6 2 warning ewb00073 avoid carbon monoxide poisoning all engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nau- sea, confusion, and eventually death. Carbon monoxide is a colorless, odorless, tasteless gas which may be pres...

  • Page 29

    3-1 3 ebu17681 description ebu17691 left view ebu17701 right view 1. Radiator cap 2. Fuel cock 3. Throttle stop screw 4. Air filter case 5. Battery 6. Fuses 7. Tail/brake light 8. Engine oil filler cap 9. Oil filter cartridge 10.Coolant reservoir 11.V-belt cooling duct check hose 1 2 3 4 5,6 7 8 9 1...

  • Page 30

    3-2 3 ebu17713 controls and instruments tip the atv you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Horn switch 5. Drive select lever 6. Multi-function display 7. Main switch 8. Auxiliary dc jack 9. Fuel ta...

  • Page 31

    4-1 4 ebu17735 instrument and control functions ebu17761 main switch the positions of the main switch are as follows: on all electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. Off all...

  • Page 32

    4-2 4 ebu26696 indicator lights and warning lights ebu17991 low-range indicator light “ ” this indicator light comes on when the transmis- sion is in the low-range position. Ebu17981 high-range indicator light “ ” this indicator light comes on when the transmis- sion is in the high-range position. E...

  • Page 33

    4-3 4 ebu17843 reverse indicator light “ ” this indicator light comes on when the transmis- sion is in the reverse position. Furthermore, this indicator light flashes when the engine is being raced for 10 seconds or more. Tip if the indicator light flashes under any other cir- cumstances or the spee...

  • Page 34

    4-4 4 tip  if the engine is stopped using the engine stop switch and the key is in the “on” position, the eps warning light comes on to indicate that the power assistance for the steering is not func- tioning.  if the steering load is too heavy (i.E., excessive steering use when the atv is traveli...

  • Page 35

    4-5 4 ebu18038 multi-function display the multi-function display is equipped with the following:  a speedometer  an odometer  two tripmeters (which show the distance trav- eled since they were last set to zero)  a clock  an hour meter (which shows the total time the key has been turned to “on”)...

  • Page 36

    4-6 4 clock → hour → clock to set the clock 1. Set the display to the clock mode. 2. Push the “ / ” button until the clock starts flashing. 3. Set the hours by pushing the “h” button. 4. Set the minutes by pushing the “m” button. 5. Push the “ / ” button, and then release it to start the clock. Ebu1...

  • Page 37

    4-7 4 ebu18062 handlebar switches ebu18081 engine stop switch “ / ” set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situa- tion. The engine will not start or ru...

  • Page 38

    4-8 4 ebu18191 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 4-10.) releas- ing the sw...

  • Page 39

    4-9 4 es with the riding speed. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are trav- eling. Ebu26607 on-command four-wheel-drive switch “2wd”/“4wd” warning ewb00164 always stop the atv before changing from two-wheel drive to four-wheel drive an...

  • Page 40

    4-10 4 ebu18256 on-command differential gear lock switch “4wd”/“lock” warning ewb00132 always stop the atv before changing from four-wheel drive to four-wheel-drive differen- tial gear lock or vice versa. The atv handles differently in four-wheel drive than in differential gear lock in some circum- ...

  • Page 41

    4-11 4 to lock the differential gear in four-wheel drive, make sure the on-command four-wheel-drive switch is pushed in to the “4wd” position. Stop the atv, move the differential gear lock lever to position (a), and then push the differential gear lock switch in to the “lock” position. When the diff...

  • Page 42

    4-12 4 to release the differential gear lock, stop the atv and push the switch to the “4wd” position. Tip  when the switch is set to “lock”, the differen- tial gear lock indicator and indicator light will flash until the differential gear is locked.  when the indicator and indicator light are flas...

  • Page 43

    4-13 4 before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. Ebu18324 speed limiter your atv is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening...

  • Page 44

    4-14 4 3. Tighten the locknut. Ebu18392 front brake lever the front brake lever is located on the right han- dlebar. To apply the front brake, pull the brake le- ver toward the handlebar grip. Ebu18443 brake pedal and rear brake lever the brake pedal is located on the right side of the atv and the r...

  • Page 45

    4-15 4 ebu18612 drive select lever the drive select lever is used to shift your atv into the low-range, high-range, neutral, reverse and park positions. See the “operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. Ebu18721 fuel tank cap ...

  • Page 46

    4-16 4 of sparks, open flames, or other sources of ignition such as the pilot lights of water heat- ers and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole. Stop filling when the fuel reaches the bottom of the filler ...

  • Page 47

    4-17 4 immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. Notice ecb00071 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 w...

  • Page 48

    4-18 4 on 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. Res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to thi...

  • Page 49

    4-19 4 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. Ebu18882 seat to remove the seat pull the seat lock lever upward and pull up the seat at the rear. To install the seat insert the projections o...

  • Page 50

    4-20 4 ebu29253 storage compartments this atv is equipped with two storage compart- ments. Notice ecb00831 do not store metal or sharply edged objects, like tools, in the storage compartments. If they must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compart...

  • Page 51

    4-21 4 the rear storage compartment is located under the seat. (see page 4-19.) when storing any documents in the storage com- partments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the atv, be careful not to let any water enter the stor- age compartments.  do ...

  • Page 52

    4-22 4 ebu18963 front carrier  do not exceed the load limit of 40.0 kg (88 lb) for the front carrier.  do not exceed the maximum load of 210.0 kg (463 lb) for the atv. Ebu18973 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...

  • Page 53

    4-23 4 adjust the spring preload as follows. Turn the spring preload adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension. Align the appropriate notch in the adjusting...

  • Page 54

    4-24 4 ebu19184 auxiliary dc jack the auxiliary dc jack is located at the front right side of the atv. The auxiliary dc jack can be used for suitable work lights, radios, etc. The auxiliary dc jack should only be used when the engine is running and the light switch is set to “off”. 1. Set the light ...

  • Page 55

    5-1 5 ebu19202 pre-operation checks ebu19225 inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual. Warning ewb00482 failure to inspect or maintain the v...

  • Page 56

    5-2 5 front brake • check operation. If soft or spongy, have yamaha dealer bleed hy- draulic system. • check brake pads for wear, and replace if necessary. • check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary. • check hydraulic system for leakage. Cor...

  • Page 57

    5-3 5 ebu19542 fuel make sure that there is sufficient fuel in the tank. (see page 4-15.) ebu19561 engine oil make sure that the engine oil is at the specified level. Add oil as necessary. (see page 8-16.) ebu19591 final gear oil make sure that the final gear oil is at the specified level. Add oil a...

  • Page 58

    5-4 5 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. If there is any leakage, the brake ...

  • Page 59

    5-5 5 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. Tire wear limit when the tire groove decreases to 3 mm (0.12 in) due to wear, replace...

  • Page 60

    5-6 5 tire information this atv is equipped with tubeless tires with valves. Warning ewb02552 use of improper tires on this atv may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by yamaha motor manuf...

  • Page 61

    5-7 5 aftermarket tires and rims the tires and rims that came with your atv were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Ebu19841 chassis fasteners make su...

  • Page 62

    6-1 6 ebu19882 operation ebu19902 read the owner’s manual carefully before riding the atv. If there is a control or function you do not understand, ask your yamaha dealer. Warning ewb00632 read the owner’s manual carefully to become familiar with all controls in order to help pre- vent any loss of c...

  • Page 63

    6-2 6 position (3): cold engine start with ambient temperature above 25 °c (80 °f). Ambient temp./starter (choke) position 5. Apply the rear brake lever. 6. Completely close the throttle lever and start the engine by pushing the start switch. Tip if the engine fails to start, release the start switc...

  • Page 64

    6-3 6 ebu20292 starting a warm engine follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. Ebu20442 operating the drive select lever and driving in reve...

  • Page 65

    6-4 6 reverse, make sure there are no people or ob- stacles behind you. When it is safe to proceed, go slowly. 1. Bring the atv to a complete stop. 2. Apply the brake pedal. The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal. 3. Shift from neutral ...

  • Page 66

    6-5 6 4. Check behind for people or obstacles, and then release the brake pedal. 5. Open the throttle lever gradually and continue to watch to the rear while backing. Ebu20683 engine break-in tip  for atvs equipped with an odometer or an hour meter, follow the figures given in km (mi) or the figure...

  • Page 67

    6-6 6 ebu20822 parking on a slope warning ewb00861 avoid parking on hills or other inclines. Parking on a hill or other incline could cause the atv to roll out of control, increasing the chance of an accident. If you must park on an incline, place the atv transversely across the incline, stop the en...

  • Page 68

    6-7 6 sold by yamaha or modifications not specifically recommended by yamaha, even if sold and in- stalled by a yamaha dealer. Aftermarket parts, accessories, and modifica- tions while you may find aftermarket products similar in design and quality to genuine yamaha accesso- ries, recognize that som...

  • Page 69

    6-8 6  never exceed the weight limits shown. An over- loaded atv can be unstable.  do not exceed the maximum tongue weight. You can measure tongue weight with a bath- room scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Ad- just the load in the trailer, if...

  • Page 70

    7-1 7 ebu21142 riding your atv u2lc61e0.Book page 1 wednesday, february 26, 2014 3:56 pm.

  • Page 71

    7-2 7 ebu30791 getting to know your atv this atv is for recreation and utility use. This sec- tion, riding your atv, provides general atv riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your at...

  • Page 72

    7-3 7 the time to learn the basic techniques well before attempting more difficult maneuvers. Become fa- miliar with this atv at slow speeds first, even if you are an experienced operator. Not recommended for children under 16 years of age. Warning ewb01391 a child under 16 should never operate an a...

  • Page 73

    7-4 7 apparel always wear the following to reduce risk of injury in an accident:  approved motorcycle helmet that fits properly  eye protection (goggles, helmet face shield, or protective eyewear)  over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants an approved helmet and o...

  • Page 74

    7-5 7 do not operate after or while consuming alco- hol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. Consuming alcohol or drugs could seriously affect your judg- ment, cause you to react more slowly, and affect your balance and perception. Warning!...

  • Page 75

    7-6 7 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 4-13....

  • Page 76

    7-7 7 drive more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice to drive slowly (shift into first gear or low drive if avail- able on this model) whenever you are carrying heavier loads or when towing a trailer...

  • Page 77

    7-8 7 an overturn. Never attempt stunts, such as wheelies or jumps. Don’t try to show off. [ewb01482] modifications and accessories never modify this atv through improper installa- tion or use of accessories or other modification. All parts and accessories added to this atv should be genuine yamaha ...

  • Page 78

    7-9 7 to prevent burns, avoid touching the exhaust sys- tem. Park the atv in a place where pedestrians or children are not likely to touch it. Be careful where you ride this atv is designed for use on unpaved surfaces only. Warning! Paved surfaces may seriously affect handling and control of the atv...

  • Page 79

    7-10 7 know your country’s laws and regulations before you ride on unpaved public streets or roads. Do not ride on any paved public street, road or motor- way. Warning! Never operate this atv on any paved street, paved road or motorway. You can collide with another vehicle. [ewb01522] know the terra...

  • Page 80

    7-11 7 terrain could cause loss of traction or atv con- trol, which could result in an accident, includ- ing an overturn. [ewb01542] 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...

  • Page 81

    7-12 7 select a large, flat, unpaved area to become famil- iar 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. Shift to t...

  • Page 82

    7-13 7 as you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the outside of the turn (opposite your desired direc- tion) and lean your upper body into the turn. Use the throttle to maintain an even speed throug...

  • Page 83

    7-14 7  never operate the atv on hills too steep for the atv or for your abilities. The atv can overturn more easily on extremely steep hills than on level surfaces or small hills.  always check the terrain carefully before you start up any hill. Never climb hills with exces- sively slippery or lo...

  • Page 84

    7-15 7 do not attempt to climb hills until you have mas- tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. To climb a hill, you need trac...

  • Page 85

    7-16 7 around and remount, following the procedure de- scribed in the owner’s manual. Warning! Stall- ing, rolling backwards or improperly dismounting while climbing a hill could result in atv overturning. If you cannot control the atv, dismount immediately on the uphill side. [ewb01803] riding down...

  • Page 86

    7-17 7 use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this atv is in “4wd”, all wheels (front and rear) are interconnected by the drive train. This...

  • Page 87

    7-18 7  shift your weight to the uphill side of the atv.  never attempt to turn the atv around on any hill until you have mastered the turning tech- nique as described in the owner’s manual on level ground. Be very careful when turning on any hill. Traversing a sloping surface on your atv requires...

  • Page 88

    7-19 7 the atv can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the atv. Drive slowly and ca...

  • Page 89

    7-20 7 1. Air filter case check hose 1. V-belt cooling duct check hose (left front side of atv) 1. Storage compartment check hose 1. V-belt case drain plug u2lc61e0.Book page 20 wednesday, february 26, 2014 3:56 pm.

  • Page 90

    7-21 7 riding over rough terrain warning ewb01652 riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always fo...

  • Page 91

    7-22 7 to reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. If the rear wheels of your atv start to slide side- ways, control can usually be regained (if there is room to do so) by steering in the dir...

  • Page 92

    7-23 7 what to do...  if your atv doesn’t turn when you want it to: bring the atv to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (see page 7-12.)  if...

  • Page 93

    8-1 8 ebu28784 periodic maintenance and adjustment ebu21675 periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most effi- cient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustmen...

  • Page 94

    8-2 8 ebu21732 owner’s manual and tool kit be sure to put this owner’s manual in the plastic bag and always carry it on the bottom of the seat as shown. Put the owner’s tool kit and low-pres- sure tire gauge under the seat. The service information included in this manual and the tools provided in th...

  • Page 95

    8-3 8 ebu21745 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. However, keep i...

  • Page 96

    8-4 8 6 * exhaust system • check for leakage and replace gasket(s) if neces- sary. • check for looseness and tighten all screw clamps and joints if necessary. √ √ √ 7 spark arrester • clean. √ √ √ no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (2...

  • Page 97

    8-5 8 ebu21868 general maintenance and lubrication chart 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. However, keep in mind that if th...

  • Page 98

    8-6 8 4 * brake hoses • check for cracks or other damage, and replace if necessary. √ √ √ √ • replace. Every 4 years 5 * brake fluid • replace. Every 2 years 6 * wheels • check runout and for damage, and replace if nec- essary. √ √ √ √ 7 * tires • check tread depth and for damage, and replace if nec...

  • Page 99

    8-7 8 13 * stabilizer bushes • check for cracks or other damage, and replace if necessary. √ √ √ 14 * rear knuckle pivots • lubricate with lithium-soap-based grease. √ √ √ 15 * steering shaft • lubricate with lithium-soap-based grease. √ √ √ 16 * steering system • check operation and repair or repla...

  • Page 100

    8-8 8 23 final gear oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ √ √ 24 cooling system • check coolant level and atv for coolant leakage, and correct if necessary. √ √ √ √ √ • replace coolant. Every 2 years 25 * moving parts and cables • lubricate. √ √ √ √ 26 * drive se...

  • Page 101

    8-9 8 ebu28392 tip  some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle.  hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal components...

  • Page 102

    8-10 8 ebu23091 removing and installing panels the panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. Ebu30262 panels a and c to remove a panel 1. Remove the seat. (see page 4-1...

  • Page 103

    8-11 8 to install a panel 1. Place the panel in its original position. 2. Install the seat. U2lc61e0.Book page 11 wednesday, february 26, 2014 3:56 pm.

  • Page 104

    8-12 8 panel b to remove the panel 1. Remove the carrier top bolts. 2. Remove the carrier bolts under the fenders, and then take the carrier off. 3. Remove the quick fastener screws, and then pull the panel upward to remove it. 1. Carrier bolt (top) 1 1 1 1. Carrier bolt (under the fenders) u2lc61e0...

  • Page 105

    8-13 8 to install the panel 1. Place the panel in the original position, and then install the quick fastener screws. 2. Place the carrier in the original position, and then install the carrier bolts under the fenders. 3. Install the carrier top bolts, and then tighten all bolts to the specified torq...

  • Page 106

    8-14 8 to install the panel place the panel in its original position. Ebu23224 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 ac- corda...

  • Page 107

    8-15 8 3. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medi- um-to-light tan (the ideal color when the atv is ridden normally). Tip if the ...

  • Page 108

    8-16 8 to install the spark plug 1. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 2. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Tip if a torque wrench is not available w...

  • Page 109

    8-17 8 tip if the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. 4. Remove the engine oil filler cap, and then wipe the engine oil dipstick off with a clean rag. 5. Inse...

  • Page 110

    8-18 8 8. Install the panel. To change the engine oil (with or without oil fil- ter cartridge replacement) 1. Place the atv on a level surface. 2. Remove panel e. (see page 8-10.) 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Place an oil pan under the engine to col...

  • Page 111

    8-19 8 tip an oil filter wrench is available at a nearby yamaha dealer. 8. Apply a thin coat of engine oil to the o-ring of the new oil filter cartridge. Tip make sure that the o-ring is properly seated. 9. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to the ...

  • Page 112

    8-20 8 10. Install panels d and c. 11. Install the engine oil drain bolt and its new gasket, and then tighten the bolt to the spec- ified torque. 12. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap. Tip be sure to wipe off sp...

  • Page 113

    8-21 8  make sure that no foreign material enters the crankcase. 13. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 14. Turn the engine off, wait at least ten minutes, and then...

  • Page 114

    8-22 8 to change the final gear oil 1. Place the atv on a level surface. 2. Remove the engine guard and the final gear case guard by removing the bolts. 3. Place an oil pan under the final gear case to collect the used oil. 4. Remove the final gear oil filler bolt, the final gear oil drain bolt and ...

  • Page 115

    8-23 8 6. Refill with the recommended final gear oil to the brim of the filler hole as shown. Notice: be sure no foreign material enters the final gear case. [ecb00422] tip if the recommended oil is not available, sae80w- 90 api gl-5 hypoid gear oil may be used instead. However, when using this oil,...

  • Page 116

    8-24 8 ebu23427 differential gear oil the differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a yamaha dealer check and repair the atv. In addition, the differential gear oil level must be checked and the oil changed as follows at the in- tervals sp...

  • Page 117

    8-25 8 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, the differential gear oil drain bolt and their gasket to drain the oil from the differential ...

  • Page 118

    8-26 8 8. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. Ebu23471 coolant the coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. Ebu27127...

  • Page 119

    8-27 8 ter since they are harmful to the engine. If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not be protected against frost and corrosion. If water has been added to the coolant, have a yamaha dealer check the antifreeze c...

  • Page 120

    8-28 8 4. Remove the front carrier and panel b. (see page 8-10.) 5. Remove the radiator cap. 6. Remove panel c. (see page 8-10.) 7. Remove the coolant reservoir cap. 8. Disconnect the coolant reservoir hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 1. Cool...

  • Page 121

    8-29 8 9. After draining the coolant, thoroughly flush the cooling system with clean tap water. 10. Install the coolant drain bolt and its new gas- ket, and then tighten the bolt to the specified torque. 11. Connect the coolant reservoir hose. 12. Pour the recommended coolant into the res- ervoir to...

  • Page 122

    8-30 8 16. Start the engine, and then check for coolant leakage. Tip if any leakage is found, have a yamaha dealer check the cooling system. 17. Install the panels and the front carrier. Ebu23647 cleaning the air filter element the air filter element should be cleaned at the in- tervals specified in...

  • Page 123

    8-31 8 4. Pull the air filter element out of the air filter case. 5. Pull off the air filter element lock plate, and then remove the sponge material from the air filter element frame. 1. Air filter case cover holder 2. Air filter case cover 1. Air filter element u2lc61e0.Book page 31 wednesday, febr...

  • Page 124

    8-32 8 6. Wash the sponge material gently but thor- oughly in solvent. Warning! Always use parts cleaning solvent to clean the sponge material. Never use low-flash-point sol- vents or gasoline to clean the sponge ma- terial because the engine could catch fire or explode. [ewb01942] 7. Squeeze the ex...

  • Page 125

    8-33 8 case. Never operate the engine with the air filter element removed. This will allow un- filtered air to enter the engine, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performanc...

  • Page 126

    8-34 8 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the tailpipe bolts and tighten them to the specified torque. Warning ewb02341 do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing,...

  • Page 127

    8-35 8 ebu23932 v-belt case drain plug after riding in water deep enough to allow it to en- ter the v-belt case, remove the v-belt case drain plug to drain the water from the case. Tip if water drains from the v-belt case after removing the plug, have a yamaha dealer check the atv as the water may a...

  • Page 128

    8-36 8 tip a diagnostic tachometer is needed to make this adjustment. 1. Start the engine and warm it up. Tip the engine is warm when it quickly responds to the throttle. 2. Remove panel c. (see page 8-10.) 3. Attach the tachometer to the spark plug lead. 4. Check the engine idling speed and, if nec...

  • Page 129

    8-37 8 ebu24048 adjusting the throttle lever free play the throttle lever free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The throttle lever free play should measure 3.0–5.0 mm (0.12–0.20 in) as shown. Periodically...

  • Page 130

    8-38 8 ebu24072 adjusting the drive select lever safety system cable the drive select lever safety system cable stretch- es with use, which can result in improper function. Therefore, the safety system cable should be checked and adjusted by a yamaha dealer at the intervals specified in the periodic...

  • Page 131

    8-39 8 tip the wheels need to be removed to check the brake pads. (see page 8-61.) ebu30321 rear brake friction plates the rear brake friction plates must be checked and, if necessary, replaced by a yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Ebu29843 ...

  • Page 132

    8-40 8  insufficient brake fluid may allow air to enter the brake system, reducing braking perfor- mance.  clean the filler cap before removing. Use only dot 4 brake fluid from a sealed contain- er.  use only the specified brake fluid; otherwise, the rubber seals may deteriorate, causing leakage....

  • Page 133

    8-41 8 ebu30345 adjusting the rear brake lever and brake pedal free play, and the brake pedal height the rear brake lever and brake pedal free play, and the brake pedal height must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Ad...

  • Page 134

    8-42 8 2. To increase the brake lever free play, turn the brake lever free play adjusting bolt in direction (a). To decrease the brake lever free play, turn the adjusting bolt in direction (b). Notice: distance a must not measure more than 12.7 mm (0.50 in). If distance a exceeds 12.7 mm (0.50 in), ...

  • Page 135

    8-43 8 the adjusting nut in direction (b). Notice: make sure that distance b measures 22 mm (0.87 in) or less. If distance b reaches 22 mm (0.87 in), adjust the brake lever free play at the brake lever again. If distance a exceeds 12.7 mm (0.50 in), have a yamaha dealer check the vehicle. [ecb01153]...

  • Page 136

    8-44 8 2. Loosen the locknut. 3. Turn the adjusting bolt in or out until the brake pedal height is within the specified limits. 4. Tighten the locknut. 5. Install the footboard by installing the bolts and nuts, and then tighten them to the speci- fied torques. 1. Footboard 2. Bolt and nut 3. Bolt 2 ...

  • Page 137

    8-45 8 tip tighten the footboard bolts in the order shown. Adjusting the brake pedal free play the brake pedal free play should measure 20.0 mm (0.79 in). If the free play is incorrect, adjust it as follows. 1. Footboard bolt a 2. Footboard bolt b 1 1 2 tightening torques: footboard bolt a: 4.0 nm (...

  • Page 138

    8-46 8 tip the brake lever free play and brake pedal height must be adjusted before adjusting the brake pedal free play. 1. Loosen the locknut. 2. To increase the brake pedal free play, turn the brake pedal free play adjusting nut in direc- tion (a). To decrease the brake pedal free play, turn the a...

  • Page 139

    8-47 8 ebu29882 brake light switches the brake light, which is activated by the brake pedal and brake levers, should come on just be- fore braking takes effect. The rear brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a yama...

  • Page 140

    8-48 8 ebu24905 checking and lubricating the cables the operation and the condition of all control ca- bles should be checked before each ride, and the cables and cable ends should be lubricated if nec- essary. If a cable is damaged or does not move smoothly, have a yamaha dealer check or replace it...

  • Page 141

    8-49 8 front brake lever rear brake lever ebu28872 checking and lubricating the brake pedal the operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. Ebu24964 checking the wheel hub bearings the front and rear wheel hub bearings must ...

  • Page 142

    8-50 8 in a wheel hub or if a wheel does not turn smooth- ly, have a yamaha dealer check the wheel hub bearings. Ebu24973 lubricating the drive shaft universal joint the drive shaft universal joint must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Tip...

  • Page 143

    8-51 8 rear ebu25023 checking the stabilizer bushes the stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a yamaha dealer replace the stabilizer bush- es if necessary. Ebu25053 lubricating the rear knuckle pivots...

  • Page 144

    8-52 8 ebu25093 lubricating the steering shaft the steering shaft must be lubricated by a yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart. Tip for parts equipped with a grease nipple, use a grease gun. Ebu2918a battery the battery is located under the sea...

  • Page 145

    8-53 8 keep out of reach of children. Notice ecb00621 never attempt to remove the battery cell seals, as this would permanently damage the battery. To remove the battery 1. Remove the seat. (see page 4-19.) 2. Remove the battery holding plate by remov- ing the bolts. 3. Disconnect the negative batte...

  • Page 146

    8-54 8 notice ecb00932 to charge a vrla (valve regulated lead acid) battery, a special (constant-voltage) battery charger is required. Using a conventional bat- tery charger will damage the battery. To store the battery  if the atv will not be used for more than one month, remove the battery, fully...

  • Page 147

    8-55 8 ebu30801 replacing a fuse the main fuse, the eps fuse, and the fuse box are located under the seat. (see page 4-19.) for non-eps models 1. Main fuse 2. Fuse box 3. Spare main fuse 1 2 3 1. Headlight fuse 2. Ignition fuse 3. Auxiliary dc jack fuse 4. Four-wheel-drive motor fuse 5. Signaling sy...

  • Page 148

    8-56 8 for eps models if a fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Notice ecb00641 to prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 1. Main fuse 2. Fuse box 3. Eps fuse 4. Spare main fuse ...

  • Page 149

    8-57 8 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Warning! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical system, which coul...

  • Page 150

    8-58 8 ebu25482 replacing a headlight bulb if a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 2. Remove the headlight bulb holder cover by pulling it off. 3. Remove the headlight bulb holder by pushing it in and turning it counte...

  • Page 151

    8-59 8 4. Remove the burnt-out bulb by pulling it out. 5. Insert a new headlight bulb into the bulb hold- er by pushing it in. Notice: do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life wi...

  • Page 152

    8-60 8 ebu25623 replacing the tail/brake light bulb if the tail/brake light bulb burns out, replace it as follows. 1. Remove the tail/brake light assembly by re- moving the nuts together with the washers. 2. Remove the tail/brake light bulb holder (to- gether with the bulb) by turning it counter- cl...

  • Page 153

    8-61 8 3. Remove the burnt-out bulb by pushing it in and turning it counterclockwise. 4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the tail/brake light assembl...

  • Page 154

    8-62 8 3. Elevate the atv and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. Ebu25702 installing a wheel 1. Place the atv on a level surface. 2. Install the wheel and the nuts. Tip  the arrow mark on the tire must point to- ward the rotating directio...

  • Page 155

    8-63 8 3. Lower the atv to the ground. 4. Tighten the wheel nuts to the specified torques. Ebu25741 troubleshooting although yamaha atvs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, fo...

  • Page 156

    8-64 8 ebu25786 troubleshooting charts starting problems or poor engine performance check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Check the battery. Supply fuel. The engine does not start. Check the battery. The engine does not start. Check the ignition. Oper...

  • Page 157

    8-65 8 engine overheating warning ewb02291 wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening. Allow any remaining pressure to escape before completely removi...

  • Page 158

    9-1 9 ebu25861 cleaning and storage ebu25882 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 w...

  • Page 159

    9-2 9 ebu25934 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a porous cover. Notice: storing the atv in a poorly ven- tilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust...

  • Page 160

    9-3 9 tively, turn the wheels a little every month in order to prevent the tires from becoming de- graded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a mo...

  • Page 161

    10-1 10 ebu25962 specifications dimensions: overall length: 1993 mm (78.5 in) overall width: 1093 mm (43.0 in) overall height: 1120 mm (44.1 in) seat height: 840 mm (33.1 in) wheelbase: 1233 mm (48.5 in) ground clearance: 245 mm (9.6 in) minimum turning radius: 3000 mm (118 in) weight: curb weight: ...

  • Page 162

    10-2 10 type: sae 5w-30, 10w-30, 10w-40, 15w-40, 20w-40 or 20w- 50 recommended engine oil grade: api service sg type or higher, jaso standard ma engine oil quantity: without oil filter cartridge replacement: 2.30 l (2.43 us qt, 2.02 imp.Qt) with oil filter cartridge replacement: 2.40 l (2.54 us qt, ...

  • Page 163

    10-3 10 clutch: clutch type: wet, centrifugal automatic transmission: primary reduction system: v-belt secondary reduction system: shaft drive secondary reduction ratio: 39/24 × 24/18 × 33/9 (7.944) transmission type: v-belt automatic operation: left hand operation reverse gear: 29/17 (1.706) low ra...

  • Page 164

    10-4 10 rear: 22.0 kpa (0.220 kgf/cm², 3.2 psi) front wheel: wheel type: panel wheel rim size: 12 x 6.0at rear wheel: wheel type: panel wheel rim size: 12 x 7.5at front brake: type: disc brake operation: right hand operation specified brake fluid: dot 4 rear brake: type: wet multiple disc brake oper...

  • Page 165

    10-5 10 coolant temperature warning light: led park indicator light: led on-command four-wheel-drive/differential gear lock indicator: lcd high-range indicator light: led low-range indicator light: led differential gear lock indicator light: led eps warning light: yfm450pf 12 v, 1.7 w yfm450phf 12 v...

  • Page 166

    11-1 11 ebu26001 consumer information ebu28202 identification numbers record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a yamaha dealer or for reference in case the atv is stolen. Vehicle identification num...

  • Page 167

    11-2 11 1. Model label u2lc61e0.Book page 2 wednesday, february 26, 2014 3:56 pm.

  • Page 168

    12-1 12 index a accessories and loading ................................................6-6 accessories, auxiliary jack ...........................................4-24 air filter element, cleaning ............................................8-30 axle boots ..............................................

  • Page 169

    12-2 12 indicator lights and warning lights ................................. 4-2 instruments, lights and switches ................................... 5-7 l label locations ............................................................... 1-1 light switch .................................................

  • Page 170

    Ebu26173 warning always : • use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. • avoid paved surfaces—pavement may seriously affect handling and control. Improper atv use can result in severe injury or death. Never use with drugs or alcohol always use an...