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  5. Owner's Manual

Yamaha GRIZZLY 450 YFM45FGY Owner's Manual

Summary of GRIZZLY 450 YFM45FGY

  • Page 1

    Yfm45fgy owner’s manual manuel du propriÉtaire manual del propietario 37s-f8199-60 read this manual carefully! It contains important safety information. Lire attentivement ce manuel! Il comprend d’importantes informations de sécurité. ¡lea este manual atentamente! Contiene indicaciones importantes a...

  • Page 2

    Printed in usa 2008.06-0.9 ×1 cr (e,f,s) yamaha motor co., ltd. Dic183.

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Owner’s manual yfm45fgy 37s-f8199-60-e0 u37s60e0.Book page 1 thursday, june 5, 2008 6:51 pm.

  • Page 4

    Ebu17152 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. Ec declaration of conformity conforming to directive 98/37/ec (make, model) to which this declaration applies, conforms to the essential health and safety requirements of dir...

  • Page 5

    Ebu17170 introduction ebu17291 congratulations on your purchase of the yamaha yfm45fgy. This atv represents the result of many years of yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this yamaha, you can now appreciate the high de...

  • Page 6

    Ebu17330 important manual information ebu17342 failure to follow the warnings contained in this manual can result in serious in- jury or death. Particularly important information is distinguished in this manual by the following notations: * product and specifications are subject to change without no...

  • Page 7

    Ebu17350 important notice ebu17370 welcome to the yamaha world of motor sports! 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 bef...

  • Page 8

    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...

  • Page 9

    Instruments, lights and switches ................ 5-7 operation .................................................. 6-1 starting a cold engine ................................ 6-1 starting a warm engine .............................. 6-3 operating the drive select lever and driving in reverse ..........

  • Page 10

    Checking the front brake lever free play ......................................................... 8-41 adjusting the brake pedal and rear brake lever free play and checking the brake pedal position ......................................... 8-42 axle boots ..............................................

  • Page 11

    1-1 1 ebu17430 safety information ebu17502 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 on hills or over o...

  • Page 12

    1-2 1 ● always inspect your atv each time you use it to make sure it is in safe operating condition. Al- ways 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 operatio...

  • Page 13

    1-3 1 steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill. Turn the atv around and remount, following the procedure described in this manual. ● alwa...

  • Page 14

    1-4 1 nition such as the pilot lights of water heat- ers and clothes dryers. Gasoline can catch fire and you could be burned. ● when transporting the atv in another vehi- cle, be sure it is kept upright and that the fuel cock is in the “off” position. Otherwise, fuel may leak out of the carburetor o...

  • Page 15

    2-1 2 ebu17660 location of the warning and specification labels 6 7 8 10 9 11 12 u37s60e0.Book page 1 thursday, june 5, 2008 6:51 pm.

  • Page 16

    2-2 2 ebu27150 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a replace- ment label from your yamaha dealer. For europe and ...

  • Page 17

    2-3 2 for europe 2 6 3 u37s60e0.Book page 3 thursday, june 5, 2008 6:51 pm.

  • Page 18

    2-4 2 for europe model: yfm450fwan max. Power: 19.4 kw mass in running order: 285 kg 37s-f155a-00 10 8 7 9 u37s60e0.Book page 4 thursday, june 5, 2008 6:51 pm.

  • Page 19

    2-5 2 for oceania 5fu-f816m-20 25 kpa, (3.6 psi) 25 kpa, (3.6 psi) 22 kpa, (3.2 psi) 22 kpa, (3.2 psi) 2 3 u37s60e0.Book page 5 thursday, june 5, 2008 6:51 pm.

  • Page 20

    2-6 2 for oceania 16 under 1p0-f816l-00 7 6 u37s60e0.Book page 6 thursday, june 5, 2008 6:51 pm.

  • Page 21

    2-7 2 for oceania warning fuel vapors can be a fire or explosion hazard. To avoid injury or death, never store fuel or flammable liquids in this storage compartment. Storage should not exceed 0.5 kg (1 lb) 37s-f151f-00 11 12 u37s60e0.Book page 7 thursday, june 5, 2008 6:51 pm.

  • Page 22

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Radiator cap 2. Fuel cock 3. Recoil starter 4. Throttle stop screw 5. Air filter case 6. Battery 7. Fuses 8. Tail/brake light 9. Engine oil filler cap 10.Oil filter cartridge 11.Coolant reservoir 12.V-belt cooling duct check hose 1...

  • Page 23

    3-2 3 ebu17712 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. Multifunction display 7. Main switch 8. Auxiliary dc jack 9. Fuel tan...

  • Page 24

    4-1 4 ebu17732 instrument and control functions ebu17760 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 25

    4-2 4 ebu17813 indicator lights and warning light ebu17842 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...

  • Page 26

    4-3 4 ● 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. Ebu17961 on-command four-wheel-drive/differential gear lock indicator “ ”/“ ” the on-command four-wheel-drive indicator “ ” comes on when the on-comm...

  • Page 27

    4-4 4 ebu18034 multifunction display the multifunction display is equipped with the fol- lowing: ● a speedometer (which shows the riding speed) ● an odometer (which shows the total distance traveled) ● two tripmeters (which show the distance trav- eled since they were last set to zero) ● a clock ● a...

  • Page 28

    4-5 4 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. Ebu18050 fuel gauge the f...

  • Page 29

    4-6 4 ebu18080 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 situation. The engine will not start or run when this switch is set to “...

  • Page 30

    4-7 4 top speed is normally limited when operating in differential gear lock. If conditions require more en- gine 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 func...

  • Page 31

    4-8 4 ● “2wd” (two-wheel drive): power is supplied to the rear wheels. ● “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. Then, the four-wheel-drive indicator “ ” c...

  • Page 32

    4-9 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 dif- ...

  • Page 33

    4-10 4 to release the differential gear lock, stop the atv and push the switch to the “4wd” position. Warning ewb00131 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 differe...

  • Page 34

    4-11 4 ● riding before the differential gear lock is proper- ly engaged (e.G., when the indicator and indica- tor light are flashing) will cause the engine speed to be limited until engagement is complete. ● when the atv is in four-wheel-drive differential gear lock, the maximum traveling speed is l...

  • Page 35

    4-12 4 ebu18321 speed limiter your atv was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of t...

  • Page 36

    4-13 4 ebu18442 brake pedal and rear brake lever the brake pedal is located on the right side of the atv and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. 1. Front brake lever 1. Brake p...

  • Page 37

    4-14 4 ebu18611 drive select lever the drive select lever is used to shift your atv into the low-range, high-range, neutral, reverse and park positions. See the “operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. Ebu18690 recoil starter...

  • Page 38

    4-15 4 ebu18752 fuel make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 1. Fuel tank cap 1. Fuel level 2. Fuel tank filler tube recommended fuel: unleaded gasoline only for europe: regular unleaded gasoline only with a research octane n...

  • Page 39

    4-16 4 tip if knocking or pinging occurs, use a different brand of gasoline or higher octane grade. Notice ecb00070 use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Warning...

  • Page 40

    4-17 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 41

    4-18 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. Ebu18880 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 42

    4-19 4 ebu29251 storage compartments this atv is equipped with two storage compart- ments. The front storage compartment is located at the front right side of the atv. To access the storage compartment, remove the storage compartment cover by turning it counterclockwise. 1. Projection 2. Seat holder...

  • Page 43

    4-20 4 the rear storage compartment is located under the seat. (see page 4-18.) when storing any documents in the storage com- partments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the atv, be careful not to let any water enter the storage compartments. Notice ...

  • Page 44

    4-21 4 ebu18961 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. Ebu18971 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 45

    4-22 4 tip a special wrench can be obtained at a yamaha dealer to make this adjustment. 1. Spring preload adjusting ring 2. Position indicator 1. Special wrench spring preload setting: minimum (soft): 1 standard: 2 maximum (hard): 5 u37s60e0.Book page 22 thursday, june 5, 2008 6:51 pm.

  • Page 46

    4-23 4 warning ewb00400 always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. Ebu19181 auxiliary dc jack the auxiliary dc jack is located at the front right side ...

  • Page 47

    4-24 4 ● if accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine start- ing 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. U37s...

  • Page 48

    5-1 5 ebu19200 pre-operation checks ebu19223 pre-operation check list before operating this atv, be sure to check the items listed in the following table. Warning ewb00480 always inspect your atv each time you use it to make sure it is in safe operating condition. Always follow the inspection and ma...

  • Page 49

    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 recommended brake fluid to specified level if necessary. • check hydraulic system for leakage. C...

  • Page 50

    5-3 5 ebu19540 fuel make sure that there is sufficient fuel in the tank. (see page 4-15.) warning ewb00520 ● do not overfill the fuel tank. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the en- gine or the sun. ● be careful not to spill fuel, es...

  • Page 51

    5-4 5 ebu28530 front and rear brakes brake levers and brake pedal ● check that there is no free play in the front brake lever. If there is free play, have a yamaha dealer check the brake system. ● check for correct free play in the rear brake lever and brake pedal. If the free play is incorrect, ad-...

  • Page 52

    5-5 5 ebu19812 tires warning ewb00592 use of improper tires on this atv, or operation of this atv with improper or uneven tire pres- sure, may cause loss of control, increasing your risk of accident. Pay attention to the following. ● the tires listed below have been approved by yamaha motor manufact...

  • Page 53

    5-6 5 rear: 250 kpa (2.5 kgf/cm², 36 psi) higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully. Ebu19821 measuring the tire pressure use the low-pressure tire gauge. Tip the low-pressure tire gauge is included as stan- dard equipment. Make two me...

  • Page 54

    5-7 5 ebu19830 tire wear limit replace the tire when the tire groove decreases to 3 mm (0.12 in). Ebu19840 chassis fasteners make sure that all nuts, bolts and screws are prop- erly tightened. Ebu19850 instruments, lights and switches check that all instruments, lights and switches are working prope...

  • Page 55

    6-1 6 ebu19880 operation ebu19900 read the owner’s manual carefully before riding the atv. Warning ewb00630 read the owner’s manual carefully to become familiar with all controls in order to help pre- vent any loss of control, which could cause an accident or injury. If there is a control or func- t...

  • Page 56

    6-2 6 4. Use the starter (choke) in reference to the fig- ure: position (1): cold engine start with ambient temperature below 5 °c (40 °f). Position (2): cold engine start with ambient temperature between 0 °c (30 °f) and 30 °c (90 °f). Position (3): cold engine start with ambient temperature above ...

  • Page 57

    6-3 6 8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to position (3) before riding. Tip the engine is warm when it responds normally to the throttle with the starter (choke) turned off. Ebu20291 starting a warm engine follow the same procedure as for start...

  • Page 58

    6-4 6 shifting: neutral to reverse and reverse to park tip the drive select lever cannot be shifted into or from reverse or park without applying the brake pedal. 1. Bring the atv to a complete stop. 2. Apply the brake pedal. 3. Shift from neutral to reverse or from reverse to park and vice versa by...

  • Page 59

    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. Warning ewb00720 improper operation in reverse could make you hit an obstacle or even a person behind you, resulting in serious injur...

  • Page 60

    6-6 6 ebu20690 parking when parking the atv, stop the engine, shift the drive select lever into the park position, and then turn the fuel cock to the “off” position. Ebu20820 parking on a slope warning ewb00860 avoid parking on hills or other inclines. Park- ing on a hill or other incline could caus...

  • Page 61

    6-7 6 ity or suitability. Choose a genuine yamaha ac- cessory, or one that is equivalent in design and quality. ● accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the atv. ● do not mount an...

  • Page 62

    6-8 6 the weight on the hitch. If you are carrying cargo and towing a trailer, include the tongue weight in the maximum atv load limit. ● 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...

  • Page 63

    7-1 7 ebu21141 riding your atv u37s60e0.Book page 1 thursday, june 5, 2008 6:51 pm.

  • Page 64

    7-2 7 ebu29231 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 65

    7-3 7 not recommended for children under 16 years of age. Warning ewb01390 a child under 16 should never operate an atv with engine size greater than 90 cc. Use by chil- dren of atvs that are not recommended for their age can lead to severe injury or death of the child. This atv is designed to carry...

  • Page 66

    7-4 7 apparel always wear an approved motorcycle helmet that fits properly. You should also wear: ● eye protection (goggles or face shield) ● gloves ● boots ● long-sleeved shirt or jacket ● long pants 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet u37s60e0.Book page 4 thursday, june ...

  • Page 67

    7-5 7 warning ewb01410 never operate this atv without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protecti...

  • Page 68

    7-6 7 in the owner’s manual. Failure to inspect the atv before operating or failure to properly maintain the atv increases the possibility of an accident or equipment damage. Warning ewb01440 always use the size and type tires specified in the owner’s manual for this atv on page 5-5. Always maintain...

  • Page 69

    7-7 7 loading and accessories use extra caution when riding the atv with addi- tional loads, such as accessories or cargo. The atv’s handling may be adversely affected. Re- duce your speed when adding additional loads. Warning ewb01460 ● never exceed the stated load capacity for this atv. ● cargo sh...

  • Page 70

    7-8 7 warning ewb01470 always keep both hands on the handlebars and both feet on the footboards of your atv during operation. 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 footboa...

  • Page 71

    7-9 7 installed and used according to instructions. Improper installation of accessories or modifi- cation of this atv may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized atv dealer. Exhaust system the exhaust system on t...

  • Page 72

    7-10 7 while riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles. Watch carefully for other vehicles. Make sure you know your country’s laws and regulations before you ride on unpaved public streets or roads. Do...

  • Page 73

    7-11 7 warning ewb01530 go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to chang- ing terrain conditions when operating the atv. Warning ewb01540 do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necess...

  • Page 74

    7-12 7 warning ewb01550 always mount a caution flag on the atv to make you more visible when operating in areas where you might not be seen by other vehicles. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- missio...

  • Page 75

    7-13 7 with the engine idling, shift the drive select lever into the low-range position or the high-range posi- tion. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off th...

  • Page 76

    7-14 7 this procedure should be practiced at slow speed many times in a large unpaved area with no obsta- cles. If an incorrect technique is used, your atv may continue to go straight. If the atv doesn’t turn, come to a stop and then practice the proce- dure again. If the riding surface is slippery ...

  • Page 77

    7-15 7 warning ewb01580 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. Practice on small- er hills before attempting large hills. It is important when climbing a hill to make...

  • Page 78

    7-16 7 warning ewb01600 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. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill...

  • Page 79

    7-17 7 could come off the ground. The atv could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the atv immediate- ly on the uphill side. Warning ewb01781 use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: ● kee...

  • Page 80

    7-18 7 when this atv is in 4wd or 4wd-lock, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the down...

  • Page 81

    7-19 7 to cross a sloping surface. Avoid slopes with slip- pery surfaces or rough terrain that may upset your balance. As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly...

  • Page 82

    7-20 7 warning ewb01640 never operate this atv in fast flowing water or in water deeper than that specified in your owner’s manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the lin...

  • Page 83

    7-21 7 cumulated. Wash the atv in fresh water if it has been operated in salt water or muddy con- ditions. 1. Air filter case check hose 1. V-belt cooling duct check hose (left front side of atv) 1. Drive select lever box check hose u37s60e0.Book page 21 thursday, june 5, 2008 6:51 pm.

  • Page 84

    7-22 7 riding over rough terrain riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the atv or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the atv as loss of cont...

  • Page 85

    7-23 7 you go over obstacles, always follow proper procedures as described in the owner’s manu- al. Sliding and skidding care should be used when riding on loose or slip- pery surfaces since the atv may slide. If unex- pected and uncorrected, sliding could lead to an accident. To reduce the tendency...

  • Page 86

    7-24 7 warning ewb01661 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 re- duce the chance of skidding or sliding out of control. What to do if... This secti...

  • Page 87

    7-25 7 brakes for proper operation when you come out of the water. Do not continue to ride your atv until you have regained adequate braking ability. (see page 7-19.) u37s60e0.Book page 25 thursday, june 5, 2008 6:51 pm.

  • Page 88

    8-1 8 ebu28782 periodic maintenance and minor repair ebu21670 safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your atv in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are expla...

  • Page 89

    8-2 8 the service information included in this manual and the tools provided in the owner’s tool kit are in- tended to assist you in the performance of preven- tive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work c...

  • Page 90

    8-3 8 ebu21742 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 91

    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 92

    8-5 8 ebu21864 general maintenance and lubrication chart no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 air filter element • clean and replace if necessary. Every 20–4...

  • Page 93

    8-6 8 9 * drive shaft univer- sal joint • lubricate with lithium-soap-based grease. √ √ √ 10 * chassis fasteners • make sure that all nuts, bolts, and screws are properly tightened. √ √ √ √ √ 11 * shock absorber as- semblies • check operation and correct if necessary. • check for oil leakage and rep...

  • Page 94

    8-7 8 ebu28390 tip ● the air filter needs more frequent service if you are riding in unusually wet or dusty areas. 22 final gear oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ √ 23 cooling system • check coolant level and atv for coolant leakage, and correct if necessary....

  • Page 95

    8-8 8 ● hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • 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. U37s60e0....

  • Page 96

    8-9 8 ebu23090 removing and installing panels the panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. Ebu27600 panels a and d to remove one of the panels 1. Remove the seat. (see...

  • Page 97

    8-10 8 to install one of the panels 1. Place the panel in its original position. U37s60e0.Book page 10 thursday, june 5, 2008 6:51 pm.

  • Page 98

    8-11 8 2. Install the seat. Panel b to remove the panel remove the bolt, and then take the panel off. To install the panel place the panel in the original position and install the bolt. Notice ecb00380 when installing the panel, be sure not to pinch the cables or wires. 1. Panel b 2. Bolt u37s60e0.B...

  • Page 99

    8-12 8 panel c 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) u37s60e0...

  • Page 100

    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 101

    8-14 8 to install the panel place the panel in the original position and install the bolts. Panel f to remove the panel pull outward on the areas shown. To install the panel place the panel in its original position. Ebu23221 checking the spark plug the spark plug is an important engine component, wh...

  • Page 102

    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 103

    8-16 8 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification. 2. Clean the surface of the spark plug g...

  • Page 104

    8-17 8 tip if a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4. Install the spark plug cap. 5. Install the panel. Ebu23326...

  • Page 105

    8-18 8 tip the engine oil should be between the minimum and maximum level marks. 6. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level. 7. Insert the dipstick into the oil filler hole, and then tighten the engine oil...

  • Page 106

    8-19 8 tip skip steps 6–10 if the oil filter cartridge is not being replaced. 6. Remove panels d and e. (see page 8-9.) 7. Remove the oil filter cartridge with an oil filter wrench. 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 t...

  • Page 107

    8-20 8 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 specified torque with a torque wrench. 10. Install panels e and d. 11. Install the engine oil drain bolt, and then tight- en it to the specified to...

  • Page 108

    8-21 8 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 spilled oil on any parts after the engine and exhaust system have cooled down. Notice ecb00300 ● in order to prevent clutch slippage (since t...

  • Page 109

    8-22 8 ebu28572 final gear oil the final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a yamaha dealer check and repair the atv. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the peri...

  • Page 110

    8-23 8 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 and the fi- nal gear oil drain bolt to drain the oil from the final gear case. 5. Install the drain b...

  • Page 111

    8-24 8 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, noise from the final gear case may occur when applying the rear brake. Notice ecb00420 be sure no foreign material enters the final gear case. 7. Install the oil...

  • Page 112

    8-25 8 ebu23422 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 113

    8-26 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 and the differential gear oil drain bolt to drain the oil from the differential gear case. 4. ...

  • Page 114

    8-27 8 7. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. Ebu23470 coolant the coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. Ebu27123...

  • Page 115

    8-28 8 notice ecb00401 ● if coolant is not available, use distilled water or soft tap water instead. Do not use hard wa- ter or salt water since it is harmful to the en- gine. ● if water has been used instead of coolant, re- place it with coolant as soon as possible, otherwise the cooling system wil...

  • Page 116

    8-29 8 4. Remove the front carrier and panel c. (see page 8-9.) 5. Remove the radiator cap. 6. Remove panel d. (see page 8-9.) 7. Remove the coolant reservoir cap. 8. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the cool- ant reservoir. 1. Coolant drain bolt 1. ...

  • Page 117

    8-30 8 9. After draining the coolant, thoroughly flush the cooling system with clean tap water. 10. Replace the coolant drain bolt washer if it is damaged, install the coolant drain bolt, and then tighten it to the specified torque. 11. Connect the coolant reservoir hose. 12. Pour the recommended co...

  • Page 118

    8-31 8 ● if water has been added to the coolant, have a yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- erwise the effectiveness of the coolant will be reduced. 14. Install the radiator cap, start the engine, let it idle for several minutes, and then turn it off...

  • Page 119

    8-32 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 u37s60e0.Book page 32 thursday, june ...

  • Page 120

    8-33 8 6. Wash the sponge material gently but thor- oughly in solvent. Warning ewb01940 always use parts cleaning solvent to clean the sponge material. Never use low-flash-point solvents or gasoline to clean the sponge mate- rial because the engine could catch fire or ex- plode. 7. Squeeze the exces...

  • Page 121

    8-34 8 11. Insert the air filter element into the air filter case, and then install the air filter case cover by hooking the holders onto the air filter case. 12. Install the seat. Tip the air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ...

  • Page 122

    8-35 8 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the bolts and tighten them to the speci- fied t...

  • Page 123

    8-36 8 ebu23930 v-belt case drain plug after riding in water deep enough to allow it to en- ter the v-belt case, remove this 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 affect other engin...

  • Page 124

    8-37 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 d. (see page 8-9.) 3. Attach the tachometer to the spark plug lead. 4. Check the engine idling speed and, if nece...

  • Page 125

    8-38 8 ebu24045 adjusting the throttle cable free play the throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in the periodic maintenance and lubrication chart. The throttle cable free play should measure 3.0– 5.0 mm (0.12–0.20 in) at the throttle lev...

  • Page 126

    8-39 8 ebu24071 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 127

    8-40 8 ebu28421 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 posi- tion of the wear indicator while applying the brake. I...

  • Page 128

    8-41 8 ● use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. ● 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...

  • Page 129

    8-42 8 warning ewb02471 operating with improperly serviced or adjust- ed brakes could cause loss of braking ability, which could lead to an accident. After servicing: ● make sure the brakes operate smoothly and that there is no free play. ● make sure the brakes do not drag. ● make sure the brakes ar...

  • Page 130

    8-43 8 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 2. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the final gear case. 1. Brake pedal free play 1. Brake lever free play 1. Locknut 2. Brake lever free play adjus...

  • Page 131

    8-44 8 3. Push the brake camshaft lever in direction (a) until it stops [apply approximately 50 n (5.0 kgf, 11.0 lbf) of force], and then turn the brake pedal free play adjusting nut on the brake ca- ble at the final gear case so that gap “a” mea- sures 2.5–3.0 mm (0.10–0.12 in). 4. Push the brake c...

  • Page 132

    8-45 8 5. Check the brake lever free play and, if neces- sary, 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. 6. Tighten the locknut at th...

  • Page 133

    8-46 8 warning ewb02080 operating with improperly serviced or adjust- ed brakes could cause loss of braking ability, which could lead to an accident. 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 c...

  • Page 134

    8-47 8 ebu24752 brake light switches the operation of the brake light switches must be checked and, if necessary, adjusted at the inter- vals specified in the periodic maintenance and lu- brication chart. The brake light switch for the brake pedal can be adjusted as follows, but the other brake ligh...

  • Page 135

    8-48 8 ebu24900 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 136

    8-49 8 tip to access the brake pedal pivot, remove panel b. (see page 8-9.) ebu24962 checking the wheel hub bearings the front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does ...

  • Page 137

    8-50 8 ebu25051 lubricating the rear knuckle pivots the rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Lubricate the pivoting points using a grease gun. Ebu25102 lubricating the steering shaft the steering shaft must be lubricated...

  • Page 138

    8-51 8 warning ewb02160 battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. Antidote: external: flush with water. Internal: drink large quantities...

  • Page 139

    8-52 8 notice ecb00930 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. If you do not have access to a constant-voltage battery charger, have a yamaha dealer charge your bat...

  • Page 140

    8-53 8 if a fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Notice ecb00640 to prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 1. Main fuse 2. Fuse box 1. Main fuse 2. Spare main fuse 1. Headlight f...

  • Page 141

    8-54 8 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Warning ewb02171 always use a fuse of the specified rating, and never use a substitute object in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical sys- tem, whic...

  • Page 142

    8-55 8 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 4. Remove the defective bulb by pulling it out. Warning ewb02220 a headlight bulb is hot when it is on and imme- diately after it is turned off. Wait for the bulb to cool before touching or removing it. You ...

  • Page 143

    8-56 8 notice ecb00650 do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affect- ed. Thoroughly clean off any dirt and finger- prints on the headlight bulb using a cloth...

  • Page 144

    8-57 8 2. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 3. Remove the defective bulb by pushing it in and turning it counterclockwise. 1. Tail/brake light assembly 2. Nut 1. Tail/brake light assembly 2. Tail/brake light bulb holder u37s60e0.Book page 57 thursday, ju...

  • Page 145

    8-58 8 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 assembly by install- ing the washers and the nuts. Ebu25651 removing a wheel 1. Place ...

  • Page 146

    8-59 8 ● tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 3. Lower the atv to the ground. 4. Tighten the wheel nuts to the specified torques. 1. Arrow mark 1. Tapered nut tightening torques: front wheel nut: 55 nm (5.5 m·kgf, 40 ...

  • Page 147

    8-60 8 ebu25740 troubleshooting although yamaha atvs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshootin...

  • Page 148

    8-61 8 ebu25782 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 compression. Supply fuel. The engine does not start. Check the compression. Operate the electric starter. 2. Compressio...

  • Page 149

    8-62 8 engine overheating warning ewb02290 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 150

    9-1 9 ebu25860 cleaning and storage ebu25880 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 151

    9-2 9 warning ewb02310 wet brakes may have reduced stopping ability, increasing the chance of an accident. Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. Ebu25932 storage short-term always store your atv in a cool, dry place and, if ...

  • Page 152

    9-3 9 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. Re...

  • Page 153

    10-1 10 ebu25960 specifications dimensions: overall length: 1991 mm (78.4 in) overall width: 1093 mm (43.0 in) overall height: 1120 mm (44.1 in) seat height: 850 mm (33.5 in) wheelbase: 1233 mm (48.5 in) ground clearance: 245 mm (9.6 in) minimum turning radius: 3000 mm (118 in) weight: with oil and ...

  • Page 154

    10-2 10 engine oil: type: sae 5w-30 or sae 10w-30 or sae 10w-40 or sae 15w-40 or sae 20w-40 or sae 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 cart...

  • Page 155

    10-3 10 type × quantity: bsr33 x 1 spark plug (s): manufacturer/model: ngk/dr8ea spark plug gap: 0.6–0.7 mm (0.024–0.028 in) clutch: clutch type: wet, centrifugal automatic transmission: primary reduction system: v-belt secondary reduction system: shaft drive secondary reduction ratio: 39/24 × 24/18...

  • Page 156

    10-4 10 minimum: front: 22.0 kpa (0.220 kgf/cm², 3.2 psi) 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: dual disc brake operation: right hand operation recommended fluid: d...

  • Page 157

    10-5 10 reverse indicator light: led 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 fuses: main fuse: 30.0 a ...

  • Page 158

    11-1 11 ebu26000 consumer information ebu26011 identification numbers record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a yamaha dealer or for ref- erence in case the atv is s...

  • Page 159

    11-2 11 the year of manufacture is listed in the vehicle identification number as shown in the illustration. Tip the vehicle identification number is used to identify your atv. Ebu26050 model label the model label is affixed at the location in the il- lustration. Record the information on this label...

  • Page 160

    11-3 11 1. Model label u37s60e0.Book page 3 thursday, june 5, 2008 6:51 pm.

  • Page 161

    Index a accessories and loading ................................................ 6-6 accessories, auxiliary jack ........................................... 4-23 air filter element, cleaning ............................................ 8-31 axle boots ...................................................

  • Page 162

    Horn switch .................................................................... 4-6 i identification numbers .................................................. 11-1 indicator lights and warning light .................................... 4-2 instruments, lights and switches ............................

  • Page 163

    V-belt cooling duct check hose .................................... 8-35 vehicle identification number ....................................... 11-1 w wheel hub bearings, checking ..................................... 8-49 wheel, installing ........................................................... ...

  • Page 164

    Yamaha motor co., ltd. Printed in usa 2008.06-0.9 ×1 cr (e) u37s60e0.Book page 1 thursday, june 5, 2008 6:51 pm.