1. DL manuals
  2. Yamaha
  3. Offroad Vehicle
  4. GRIZZLY 550 FI YFM5FGPSEY
  5. Owner's Manual

Yamaha GRIZZLY 550 FI YFM5FGPSEY Owner's Manual

Summary of GRIZZLY 550 FI YFM5FGPSEY

  • Page 1

    Yfm7fgpy owner’s manual manuel du propriÉtaire manual del propietario 43p-28199-61 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 indicaciones importantes a...

  • Page 2

    Printed in japan 2008.10-0.6 ×1 cr (e,f,s) printed on recycled paper imprimÉ sur papier recyclÉ impreso en papel reciclado yamaha motor co., ltd. Dic183.

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Owner’s manual yfm7fgpy 43p-28199-61-e0 u43p61e0.Book page 1 friday, october 17, 2008 2:18 pm.

  • Page 4

    Ebu27851 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 yfm7fgpy. 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

    Operating the drive select lever and driving in reverse ...................................... 6-2 engine break-in .......................................... 6-4 parking ....................................................... 6-5 parking on a slope ..................................... 6-5 accessori...

  • Page 10

    Checking and lubricating the cables ........ 8-52 checking and lubricating the front and rear brake levers .................................... 8-52 checking and lubricating the brake pedal ...................................................... 8-53 checking the wheel hub bearings ............ 8-53 ...

  • Page 11

    1-1 1 ebu17430 safety information ebu27250 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. Otherwise, fuel may leak out of the fuel tank. ● gasoline is poisonous. If you should swal- low ...

  • Page 15

    2-1 2 ebu17660 location of the warning and specification labels u43p61e0.Book page 1 friday, october 17, 2008 2:18 pm.

  • Page 16

    2-2 2 ebu17670 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a replace- ment label from your yamaha dealer. U43p61e0.Book p...

  • Page 17

    2-3 2 u43p61e0.Book page 3 friday, october 17, 2008 2:18 pm.

  • Page 18

    2-4 2 u43p61e0.Book page 4 friday, october 17, 2008 2:18 pm.

  • Page 19

    2-5 2 u43p61e0.Book page 5 friday, october 17, 2008 2:18 pm.

  • Page 20

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Radiator cap 2. Battery 3. Fuses 4. Air filter case 5. Spark arrester 6. Engine oil dipstick 7. Oil filter cartridge 8. Coolant reservoir 1. Rear shock absorber assembly spring preload adjusting ring 2. Rear storage compartment and...

  • Page 21

    3-2 3 ebu17712 controls and instruments tip the atv you have purchased may differ slightly from the figures shown in this manual. 1. Drive select lever 2. Rear brake lever 3. Handlebar switches 4. Horn switch 5. Rear brake fluid reservoir 6. Multifunction display 7. Front brake fluid reservoir 8. On...

  • Page 22

    4-1 4 ebu17733 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 23

    4-2 4 ebu26692 indicator lights and warning lights ebu17830 reverse indicator light “ ” this indicator light comes on when the transmis- sion is in the reverse position. Ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu28662 co...

  • Page 24

    4-3 4 ● the engine may also overheat if mud or dirt has accumulated on the radiator (i.E., after riding in wet terrain). In this case, see page 8-19 for an explanation on how to access the radiator. ● start the engine after making sure that the warning light is out. Continuous use while the warning ...

  • Page 25

    4-4 4 the on-command differential gear lock indicator “ ” in the on-command four-wheel- drive indicator also comes on when the on-com- mand differential gear lock switch is set to the “lock” position. Tip ● due to the synchronizing mechanism in the dif- ferential gear case, the four-wheel-drive indi...

  • Page 26

    4-5 4 ebu27295 multifunction display the multifunction display is equipped with the fol- lowing: ● 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 engine has been running) ● a...

  • Page 27

    4-6 4 to set the clock 1. Set the display to the clock mode. 2. Push the “select” button and “reset” but- ton together for at least three seconds. 3. When the hour digits start flashing, push the “reset” button to set the hours. 4. Push the “select” button, and the minute digits will start flashing....

  • Page 28

    4-7 4 self-diagnosis device this model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the multifunction display will indicate an error code. If the multifunction display indicates such an error code, note the code number...

  • Page 29

    4-8 4 ebu18100 start switch “ ” push this switch to crank the engine with the start- er. Notice ecb00050 see the starting instructions on page 6-1 prior to starting the engine. Ebu18151 light switch “ / /off” set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to...

  • Page 30

    4-9 4 tip if the digits of the speedometer appear as shown when the switch is not being pushed, this could indicate a malfunction in the electrical system. In this case, take the atv to a yamaha dealer at the first opportunity. Warning ewb00150 always ride at a slow speed when the atv is in four-whe...

  • Page 31

    4-10 4 warning ewb00163 always stop the atv before changing from two-wheel drive to four-wheel drive and vice versa. The atv handles differently in two- wheel drive than in four-wheel drive in some circumstances. Changing from two-wheel drive to four-wheel drive or vice versa while moving may cause ...

  • Page 32

    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 dif-...

  • Page 33

    4-12 4 pectedly. This could distract the operator and increase the risk of losing control and causing an accident. Warning ewb00140 always ride at a slow speed when the atv is in differential gear lock, and allow extra time and distance for maneuvers. All wheels turn at the same speed when the dif- ...

  • Page 34

    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. Warning ewb00250 malfunction of the throttle could make it diffi- cult to speed up or slow down when you need to. This could cause an...

  • Page 35

    4-14 4 3. Tighten the locknut. Warning ewb00240 improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttl...

  • Page 36

    4-15 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 6-2 for the drive select lever operation. Ebu27350 fuel tank cap ...

  • Page 37

    4-16 4 to install the fuel tank cap install the fuel tank cap by turning it clockwise until a click is heard, and then close the fuel tank cap cover. Ebu28940 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 cove...

  • Page 38

    4-17 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 39

    4-18 4 to install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Tip make sure that the seat is securely fitted. Ebu27361 storage compartments this atv is equipped with two storage compart- ments. The front storage compartment is...

  • Page 40

    4-19 4 the rear storage compartment is located under the seat. (see page 4-17.) to access the storage com- partment, remove the storage compartment cover. 1. Front storage compartment 1. Rear storage compartment cover 1. Rear storage compartment u43p61e0.Book page 19 friday, october 17, 2008 2:18 pm.

  • Page 41

    4-20 4 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 ecb00830 do not store metal or sharply edged objects, like tools, in the ...

  • Page 42

    4-21 4 ebu18961 front carrier ● do not exceed the load limit of 45.0 kg (99 lb) for the front carrier. ● do not exceed the maximum load of 220.0 kg (485 lb) for the atv. Ebu18971 rear carrier ● do not exceed the load limit of 85.0 kg (187 lb) for the rear carrier. ● do not exceed the maximum load of...

  • Page 43

    4-22 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 44

    4-23 4 4. When the auxiliary dc jack is not being used, cover it with the cap. Notice ecb00120 ● do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. ● if accessories are used without the engine running or with the headlight...

  • Page 45

    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 46

    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 47

    5-3 5 ebu19540 fuel make sure that there is sufficient fuel in the tank. (see page 4-16.) 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 48

    5-4 5 ebu29080 front and rear brakes brake levers and brake pedal ● check that there is no free play in the front and rear brake levers. If there is free play, have a yamaha dealer check the brake system. ● check for correct free play in the brake pedal. If the free play is incorrect, adjust it. (se...

  • Page 49

    5-5 5 ebu19792 tires warning ewb00602 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 co., ltd...

  • Page 50

    5-6 5 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 measurements of the tire pressure and ...

  • Page 51

    5-7 5 ebu19840 chassis fasteners make sure that all nuts, bolts and screws are prop- erly tightened. Ebu19850 instruments, lights and switches check that all instruments, lights and switches are working properly. Correct if necessary. 1. Tire wear limit u43p61e0.Book page 7 friday, october 17, 2008 ...

  • Page 52

    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 53

    6-2 6 tip this model is equipped with an ignition circuit cut- off system. The engine can be started under the following conditions: ● the drive select lever is in the neutral or park po- sition. ● the rear brake lever or brake pedal is applied with the drive select lever in any position. How- ever,...

  • Page 54

    6-3 6 3. Release the brake pedal, and then open the throttle lever gradually. 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....

  • Page 55

    6-4 6 ● due to the synchronizing mechanism in the en- gine, the indicator light may not come on until the atv starts moving. 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 ewb007...

  • Page 56

    6-5 6 notice ecb00220 if any engine trouble should occur during the engine break-in period, immediately have a yamaha dealer check the atv. Ebu27321 parking when parking the atv, stop the engine, and shift the drive select lever into the park position. Ebu20820 parking on a slope warning ewb00860 av...

  • Page 57

    6-6 6 ● choose only accessories designed for your atv. Your yamaha dealer has a variety of gen- uine yamaha accessories. Other accessories may also be available on the market. However, it is not possible for yamaha to test all non- yamaha accessories, nor control over their qual- ity or suitability....

  • Page 58

    6-7 6 ● 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 necessary, to reduce the weight on the hitch. If you are carrying cargo and ...

  • Page 59

    6-8 6 warning ewb00820 never exceed the stated load capacity for this atv. Overloading this atv or carrying or tow- ing cargo improperly could cause changes in atv handling which could lead to an accident. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo...

  • Page 60

    7-1 7 ebu21141 riding your atv u43p61e0.Book page 1 friday, october 17, 2008 2:18 pm.

  • Page 61

    7-2 7 ebu27413 getting to know your atv this atv is mainly for utility use, but may also be used for recreation. This section, riding your atv, provides general atv riding instructions for recre- ational riding. The skills and techniques described in this section, however, are appropriate for all ty...

  • Page 62

    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 63

    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 u43p61e0.Book page 4 friday, october...

  • Page 64

    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 65

    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 66

    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 67

    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 68

    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 69

    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 70

    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 71

    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 72

    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 73

    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 74

    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 75

    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 76

    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 ewb01801 use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: ● kee...

  • Page 77

    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 78

    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 79

    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 80

    7-21 7 1. Air filter case check hose 1. Air filter case check hose 1. Storage compartment drain plug 1. Storage compartment drain plug u43p61e0.Book page 21 friday, october 17, 2008 2:18 pm.

  • Page 81

    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 82

    7-23 7 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 direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide. With practice, over a period of time, ski...

  • Page 83

    7-24 7 ● if your atv starts to slide sideways: steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (see page 7-22.) ● if your atv can’t make it up a hill you are trying to climb: turn the atv around if y...

  • Page 84

    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 85

    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 86

    8-3 8 ebu21743 periodic maintenance chart for the emission control system tip ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep i...

  • Page 87

    8-4 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 88

    8-5 8 8 * wheel hub bearings • check for looseness or damage, and replace if necessary. √ √ √ √ 9 * v-belt • check for wear, cracks or other damage, and re- place if necessary. √ √ √ √ 10 * chassis fasteners • make sure that all nuts, bolts, and screws are properly tightened. √ √ √ √ √ 11 * shock ab...

  • Page 89

    8-6 8 20 differential gear oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ 21 final gear oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ 22 cooling system • check coolant level and atv for coolant leakage, and correct if necessary. √ √ √ √ √ • re...

  • Page 90

    8-7 8 ebu23071 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 91

    8-8 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. Ebu27382 panel a to remove the panel pull upward on the areas shown. 1. Pane...

  • Page 92

    8-9 8 to install the panel place the panel in the original position. Panel b to remove the panel 1. Remove panel a. 2. Remove the front carrier by removing the bolts. 1. Panel a 1. Carrier bolt (under the fenders) u43p61e0.Book page 9 friday, october 17, 2008 2:18 pm.

  • Page 93

    8-10 8 3. Remove the front carrier stays by removing the bolts. 4. Remove the quick fasteners, and then pull the panel upward to remove it. 1. Carrier bolt (top) 1. Front carrier stay 1. Front carrier stay bolt u43p61e0.Book page 10 friday, october 17, 2008 2:18 pm.

  • Page 94

    8-11 8 to install the panel 1. Place the panel in the original position, and then install the quick fasteners. 2. Install the front carrier stays by installing the bolts and tightening them to the specified torque. 3. Install the front carrier by installing the bolts and tightening them to the speci...

  • Page 95

    8-12 8 4. Install panel a. Panel c to remove the panel 1. Remove the seat. (see page 4-17.) 2. Remove panel a. 3. Remove the quick fastener screws, and then pull the panel upward to remove it. To install the panel 1. Place the panel in the original position, and then install the quick fastener screw...

  • Page 96

    8-13 8 2. Install panel a. 3. Install the seat. Panels d and e to remove one of the panels 1. Remove panel c. 2. Remove the quick fastener screw and bolt, and then pull the panel upward to remove it. Tip to ease removal of panel d, shift the drive select lever into the reverse position. 1. Panel d 2...

  • Page 97

    8-14 8 to install one of the panels 1. Place the panel in the original position, and then install the bolt and quick fastener screw. 2. Install panel c. 1. Panel e 2. Quick fastener screw 1. Bolt u43p61e0.Book page 14 friday, october 17, 2008 2:18 pm.

  • Page 98

    8-15 8 panel f to remove the panel pull outward on the areas shown. To install the panel place the panel in the original position. Panels g and h to remove one of the panels remove the nut and bolts, and then pull the panel downward while pushing the projection. 1. Panel f u43p61e0.Book page 15 frid...

  • Page 99

    8-16 8 to install one of the panels place the panel in the original position, and then in- stall the bolts and nut. 1. Panel g 2. Nut 3. Bolt 4. Projection 1. Panel h 2. Nut 3. Bolt 4. Projection u43p61e0.Book page 16 friday, october 17, 2008 2:18 pm.

  • Page 100

    8-17 8 panel i to remove the panel 1. Remove the seat. (see page 4-17.) 2. Remove the rear carrier by removing the bolts. 1. Carrier bolt (under the fenders) 1. Carrier bolt (upper) u43p61e0.Book page 17 friday, october 17, 2008 2:18 pm.

  • Page 101

    8-18 8 3. Remove the quick fasteners, and then push inward on the areas shown. To install the panel 1. Place the panel in the original position, and then install the quick fasteners. 1. Carrier bolt (lower) 1. Panel i 2. Quick fastener u43p61e0.Book page 18 friday, october 17, 2008 2:18 pm.

  • Page 102

    8-19 8 2. Install the rear carrier by installing the bolts and tightening them to the specified torques. 3. Install the seat. Ebu28671 removing the radiator grills the radiator grills can be removed to access the radiator for cleaning. To remove a radiator grill remove the quick fastener, pull the r...

  • Page 103

    8-20 8 ebu23211 checking the spark plug the spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart. In a...

  • Page 104

    8-21 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 105

    8-22 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. Ebu27462 engine oil and oil fi...

  • Page 106

    8-23 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 completely into the oil filler hole. 8. Install the panel...

  • Page 107

    8-24 8 tip skip steps 5–9 if the oil filter cartridge is not being replaced. 5. Remove panel g. (see page 8-8.) 6. Remove the oil filter cartridge with an oil filter wrench. Tip an oil filter wrench is available at a nearby yamaha dealer. 7. Apply a thin coat of engine oil to the o-ring of the new o...

  • Page 108

    8-25 8 9. Install panel g. 10. Install the engine oil drain bolt, and then tight- en it to the specified torque. 11. Refill with the specified amount of the recom- mended engine oil, and then insert the dip- stick completely into the oil filler hole. Tip be sure to wipe off spilled oil on any parts ...

  • Page 109

    8-26 8 ● make sure that no foreign material enters the crankcase. 12. 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. 13. Turn the engine off, wait at least ten minutes, and then...

  • Page 110

    8-27 8 3. If the oil is below the brim of the check hole, remove the final gear oil filler bolt, and then add sufficient oil of the recommended type to raise it to the correct level. 4. Install the oil level check bolt and oil filler bolt, and then tighten them to the specified torques. To change th...

  • Page 111

    8-28 8 3. Remove the final gear oil filler bolt, final gear oil level check bolt, and the final gear oil drain bolt to drain the oil from the final gear case. 4. Install the drain bolt, and then tighten it to the specified torque. 5. Refill with the recommended final gear oil to the brim of the chec...

  • Page 112

    8-29 8 7. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 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 differenti...

  • Page 113

    8-30 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

    8-31 8 notice ecb00410 be sure no foreign material enters the differen- tial gear case. 6. Install the oil filler bolt, and then tighten it to the specified torque. 7. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. Ebu23470 coolant the coolant level shoul...

  • Page 115

    8-32 8 4. Remove the coolant reservoir cap, add cool- ant or distilled water to the maximum level mark, install the reservoir cap, and then install the panel. 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 ...

  • Page 116

    8-33 8 ebu27761 to change the coolant warning ewb01890 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 place a thick rag over the cap when opening. Allow any remaining pressure to escape before com...

  • Page 117

    8-34 8 6. Remove the coolant reservoir cap. 7. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the cool- ant reservoir. 8. After draining the coolant, thoroughly flush the cooling system with clean tap water. 9. Replace the coolant drain bolt washer if it is damage...

  • Page 118

    8-35 8 12. Pour the recommended coolant into the reser- voir to the maximum level mark, and then in- stall the reservoir cap. 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 ...

  • Page 119

    8-36 8 15. Remove panel e. (see page 8-8.) 16. Loosen the clamp screw, and then remove the v-belt cooling duct. 17. Loosen the cylinder head air bleed bolt, with- out removing it, to allow all of the air to escape from the air bleed bolt hole. 18. When coolant begins to flow out of the bolt hole, ti...

  • Page 120

    8-37 8 22. Stop the engine and allow it to cool. If the cool- ant level has dropped after the engine has cooled, add sufficient coolant until it reaches the top of the radiator, and then install the ra- diator cap. 23. Start the engine, and then check for coolant leakage. Tip if any leakage is found...

  • Page 121

    8-38 8 1. Place the atv on a level surface. 2. Remove panel c. (see page 8-8.) 3. Remove the air filter case cover by unhooking the holders. 4. Remove the sponge material and the mesh from the air filter case. 1. Air filter case check hose 1. Air filter case cover holder 2. Air filter case cover u43...

  • Page 122

    8-39 8 5. Clean the mesh with solvent, and then wipe the solvent off. 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 becau...

  • Page 123

    8-40 8 11. Insert the projections on the air filter case cov- er into the holders on the air filter case, and then install the air filter case cover by hooking the holders onto the cover. 12. Place the hoses in their original position as shown. 13. Install the panel. Tip the air filter element shoul...

  • Page 124

    8-41 8 notice ecb00760 ● make sure that the air filter element is prop- erly seated in the air filter case. ● never operate the engine with the air filter el- ement removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage. Addition- ally, oper...

  • Page 125

    8-42 8 4. Install the gasket, and then insert the tailpipe into the muffler and align the bolt holes. 5. Install the bolts and tighten them to the speci- fied torque. 6. Remove the purging bolt. 7. Start the engine and rev it up approximately twenty times while momentarily creating ex- haust system ...

  • Page 126

    8-43 8 warning ewb02380 never run the engine in an enclosed area when purging the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monox- ide poisoning, possibly leading to death, and start a fire. ● always let the exhaust system cool prior to touching exhaust components. ●...

  • Page 127

    8-44 8 tip the engine idling speed must be checked, and ad- justed if necessary, before adjusting the throttle ca- ble free play. 1. Slide the rubber cover back. 2. Loosen the locknut. 3. To increase the throttle cable free play, turn the throttle cable free play adjusting bolt in di- rection (a). T...

  • Page 128

    8-45 8 lows you to check the brake pad wear without hav- ing to disassemble the brake. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a yamaha dealer re- place the brake pads as a set. Tip the wheels need to be removed to check the brake pads. (see p...

  • Page 129

    8-46 8 tip the wheels need to be removed to check the brake hose protectors. (see page 8-63.) ebu24251 checking the brake fluid level insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the ...

  • Page 130

    8-47 8 rear brake observe these precautions: ● when checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. ● refill with the same...

  • Page 131

    8-48 8 ebu27771 checking the front and rear brake lever free play the front and rear brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake le- vers should have no free play as shown. If there is free play, have a yamaha dealer c...

  • Page 132

    8-49 8 replacement of brake components requires professional knowledge. These procedures should be performed by a yamaha dealer. Ebu29071 adjusting the brake pedal free play the brake pedal free play must be adjusted at the intervals specified in the periodic maintenance and lubrication chart. Tip ●...

  • Page 133

    8-50 8 4. Tighten the locknut. 5. After adjusting, there should be slight play at the brake pedal cable joint as shown. If there is no play, repeat steps 2 to 4. 6. Install the panel. If the correct free play cannot be obtained, have a yamaha dealer adjust it. Tip when adjusting the rear brake pedal...

  • Page 134

    8-51 8 warning ewb02070 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. ● make sure the brakes...

  • Page 135

    8-52 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

    8-53 8 rear brake lever ebu28832 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. Tip to access the brake pedal pivot, remove panel h. (see page 8-8.) ebu24962 checking the wheel hub b...

  • Page 137

    8-54 8 have a yamaha dealer replace the stabilizer bush- es if necessary. 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 l...

  • Page 138

    8-55 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

    8-56 8 5. Pull the battery out of its compartment. To charge the battery have a yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the atv is equipped with optional electri- cal accessories. Notice ecb...

  • Page 140

    8-57 8 to install the battery tip be sure the battery is fully charged. 1. Place the battery in its compartment. 2. Connect the positive battery lead first, then connect the negative battery lead by installing their bolt. 3. Install the battery holding plate by installing the nuts. 4. Install the fr...

  • Page 141

    8-58 8 the main fuse, the fuel injection system fuse, the eps fuse, and the fuse box are located under pan- el a. (see page 8-8.) 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...

  • Page 142

    8-59 8 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, which could lead to a fire. 3. Turn the key to “on” and turn on the electrical circui...

  • Page 143

    8-60 8 2. Remove the headlight bulb cover. 3. Disconnect the headlight coupler. 4. Unhook the headlight bulb holder, and then remove the burnt-out bulb. 1. Cover at the rear of the headlight 1. Headlight bulb cover 1. Headlight coupler u43p61e0.Book page 60 friday, october 17, 2008 2:18 pm.

  • Page 144

    8-61 8 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 can be burned or a fire could start if the bulb touch- es something flammable. 5. Place a new headlight bulb into position, and then s...

  • Page 145

    8-62 8 notice ecb00670 make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 9. Adjust the headlight beam if necessary. Ebu25551 adjusting a headlight beam notice ecb00690 it is advisable to have a yamaha dealer make this adjustment. To raise a headli...

  • Page 146

    8-63 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 panel. Ebu25651 removing...

  • Page 147

    8-64 8 ebu25701 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 toward the rotating direction of the wheel. ● tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- ...

  • Page 148

    8-65 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 149

    8-66 8 ebu27691 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 150

    8-67 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 151

    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 152

    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. Ebu27260 storage short-term always store your atv in a cool, dry place and, if ...

  • Page 153

    9-3 9 e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. 4. Lubricate all control cables and the pivoting points of all levers and pedals. 5. Check and, if necessary, correct the tire air pressure, and then block up the atv so that all of its wh...

  • Page 154

    10-1 10 ebu25960 specifications dimensions: overall length: 2065 mm (81.3 in) overall width: 1180 mm (46.5 in) overall height: 1240 mm (48.8 in) seat height: 905 mm (35.6 in) wheelbase: 1250 mm (49.2 in) ground clearance: 275 mm (10.8 in) minimum turning radius: 3200 mm (126 in) weight: with oil and...

  • Page 155

    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: 2.00 l (2.11 us qt, 1.76 imp.Qt) with oil filter cart...

  • Page 156

    10-3 10 clutch: clutch type: wet, centrifugal automatic transmission: primary reduction system: v-belt secondary reduction system: shaft drive secondary reduction ratio: 41/21 × 24/18 × 33/9 (9.544) transmission type: v-belt automatic operation: left hand operation reverse gear: 23/14 × 28/23 (2.000...

  • Page 157

    10-4 10 rear wheel: wheel type: panel wheel rim size: 12 x 7.5at front brake: type: dual disc brake operation: right hand operation recommended fluid: dot 4 rear brake: type: dual disc brake operation: left hand and right foot operation recommended fluid: dot 4 front suspension: type: double wishbon...

  • Page 158

    10-5 10 eps 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: 40.0 a fuel injection system fuse: 15.0 a eps fuse: ...

  • Page 159

    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 160

    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 161

    11-3 11 1. Model label u43p61e0.Book page 3 friday, october 17, 2008 2:18 pm.

  • Page 162

    Index a accessories and loading ................................................ 6-5 accessories, auxiliary jack ........................................... 4-22 air filter element, cleaning ............................................ 8-37 axle boots ...................................................

  • Page 163

    K key identification number ............................................. 11-1 l label locations ............................................................... 2-1 light switch .................................................................... 4-8 low-range indicator light ..........................

  • Page 164

    Yamaha motor co., ltd. Printed on recycled paper printed in japan 2008.10-0.6 ×1 cr (e) u43p61e0.Book page 1 friday, october 17, 2008 2:18 pm.