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Yamaha GRIZZLY 700 FI YFM7FGPW Owner's Manual - Owner’S Manual

Other manuals for GRIZZLY 700 FI YFM7FGPW: Owner's Manual, Service Manual

Summary of GRIZZLY 700 FI YFM7FGPW

  • Page 1

    Yfm7fgpw owner’s manual manuel du propriÉtaire manual del propietario 3b4-28199-60

  • Page 2

    Printed in japan 2006.05-1.4 ×1 cr (e,f,s) printed on recycled paper imprimÉ sur papier recyclÉ impreso en papel reciclado yamaha motor co., ltd..

  • Page 3: Owner’S Manual

    Owner’s manual yfm7fgpw 3b4-28199-60-e0 u3b460e0.Book page 1 friday, may 12, 2006 2:51 pm.

  • Page 4

    Ebu27850 declare in sole responsibility, that the product ec declaration of conformity conforming to directive 98/37/ec yamaha motor co., ltd. (name of supplier) 2500 shingai, iwata, shizuoka, japan (make, model) to which this declaration applies, conforms to the essential health and safety requirem...

  • Page 5

    Ebu17170 introduction ebu17290 congratulations on your purchase of the yamaha yfm7fgpw. 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 ebu17341 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 front and rear brake levers .................................... 8-52 checking and lubricating the brake pedal ...................................................... 8-53 checking the wheel bearings ................... 8-53 lubricating the drive shaft universal joint ......

  • 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 u3b460e0.Book page 1 friday, may 12, 2006 2:51 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 u3b460e0.Book page 3 friday, may 12, 2006 2:51 pm.

  • Page 18

    2-4 2 for europe u3b460e0.Book page 4 friday, may 12, 2006 2:51 pm.

  • Page 19

    2-5 2 for europe u3b460e0.Book page 5 friday, may 12, 2006 2:51 pm.

  • Page 20

    2-6 2 for oceania u3b460e0.Book page 6 friday, may 12, 2006 2:51 pm.

  • Page 21

    2-7 2 for oceania u3b460e0.Book page 7 friday, may 12, 2006 2:51 pm.

  • Page 22

    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 23

    3-2 3 ebu17712 controls and instruments note: 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 meter unit 7. Front brake fluid reservoir ...

  • Page 24

    4-1 4 ebu17730 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 ebu26691 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. Ebu17900 co...

  • 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. Ebu27280 engine trouble warning light “ ” this warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When ...

  • Page 27

    4-4 4 note: ● due to the synchronizing mechanism in the dif- ferential gear case, the four-wheel-drive indica- tor may not come on until the atv starts moving. ● when the on-command differential gear lock switch is set to “lock”, the indicator “ ” will flash until the differential gear is locked. Eb...

  • Page 28

    4-5 4 ebu27291 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 29

    4-6 4 clock → hour → clock 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...

  • Page 30

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

  • Page 31

    4-8 4 ebu18100 start switch “ ” push this switch to crank the engine with the start- er. Caution: 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 “ ” ...

  • Page 32

    4-9 4 note: 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-w...

  • Page 33

    4-10 4 warning ewb00161 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 34

    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 35

    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 36

    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 37

    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 38

    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 39

    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. Ebu18750 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 40

    4-17 4 note: if knocking or pinging occurs, use a different brand of gasoline or higher octane grade. Caution: 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. War...

  • Page 41

    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. Note: make sure that the seat is securely fitted. Ebu27361 storage compartments this atv is equipped with two storage compart- ments. The front storage compartment ...

  • Page 42

    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 u3b460e0.Book page 19 friday, may 12, 2006 2:51 pm.

  • Page 43

    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. Caution: ecb00830 do not store metal or sharply edged objects, like tools, in th...

  • Page 44

    4-21 4 ebu18960 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. Ebu18970 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 45

    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. Ebu19180 auxiliary dc jack the auxiliary dc jack is located at the front right side ...

  • Page 46

    4-23 4 4. When the auxiliary dc jack is not being used, cover it with the cap. Caution: 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 headlig...

  • Page 47

    5-1 5 ebu19200 pre-operation checks ebu19220 pre-operation check list before operating this atv, be sure to check the items listed in the following table. Note: the maintenance of some items in the table has to be performed by a yamaha dealer. Refer to the “periodic maintenance and lubrication chart...

  • Page 48

    5-2 5 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 maintenance procedures and schedules described in the owner’s manual. Failure to inspect increases the possibility of an accident or equipment damage. ...

  • Page 49

    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 50

    5-4 5 ebu27790 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 51

    5-5 5 ebu19761 throttle lever check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a yamaha dealer correct if necessary. Ebu19791 tires warning ewb00601 use of improper tires on this atv, or operation of this atv with improper or u...

  • Page 52

    5-6 5 minimum tire pressure: front: 32.0 kpa (4.6 psi) (0.320 kgf/cm²) rear: 27.0 kpa (3.9 psi) (0.270 kgf/cm²) • use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: front: 250 kpa (36 psi) (2.5 kgf/cm²) rear: 250 kpa (36 psi) (2.5 kgf/cm²) higher pre...

  • Page 53

    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 54

    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 55

    6-2 6 note: 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- eve...

  • Page 56

    6-3 6 note: make sure that the drive select lever is completely shifted into position. 3. Release the brake pedal, and then open the throttle lever gradually. Shifting: neutral to reverse and reverse to park note: the drive select lever cannot be shifted into or from reverse or park without applying...

  • Page 57

    6-4 6 note: ● when in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a yamaha dealer check the elec- trical circuit. ● due to the synchronizing mechanism in the en- gine, the indicator light may not come on until the atv starts moving. 4. Check beh...

  • Page 58

    6-5 6 0–10 hours avoid prolonged operation above 1/2 throttle. Vary the speed of the atv regularly. Do not operate it at one set throttle position. 10–20 hours avoid prolonged operation above 3/4 throttle. Rev the engine freely, but do not use full throttle at any time. 20 hours and beyond the atv c...

  • Page 59

    6-6 6 ebu20910 accessories and loading ebu20920 accessories accessories can affect the handling and control of your atv. Keep the following in mind when consid- ering an accessory or operating an atv which has accessories. ● choose only accessories designed for your atv. Your yamaha dealer has a var...

  • Page 60

    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 61

    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 62

    7-1 7 ebu21141 riding your atv u3b460e0.Book page 1 friday, may 12, 2006 2:51 pm.

  • Page 63

    7-2 7 ebu27411 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 64

    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 65

    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 u3b460e0.Book page 4 friday, may 12,...

  • Page 66

    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 67

    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 68

    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 69

    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 70

    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 71

    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 72

    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 73

    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 74

    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 75

    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 76

    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 77

    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 78

    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 79

    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 80

    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 81

    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 82

    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 u3b460e0.Book page 21 friday, may 12, 2006 2:51 pm.

  • Page 83

    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 84

    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 85

    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 86

    8-1 8 ebu21653 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 87

    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 88

    8-3 8 ebu22403 periodic maintenance and lubrication chart note: ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep in mind that if...

  • Page 89

    8-4 8 6 * rear brake • check operation and correct if necessary. • check brake pedal free play and adjust if neces- sary. • check fluid level and atv for fluid leakage, and correct if necessary. √ √ √ √ √ • replace brake pads. Whenever worn to the limit 7 * brake hoses • check for cracks or other da...

  • Page 90

    8-5 8 15 * chassis fasteners • make sure that all nuts, bolts, and screws are properly tightened. √ √ √ √ √ 16 * shock absorber as- semblies • check operation and correct if necessary. • check for oil leakage and replace if necessary. √ √ √ 17 * stabilizer bushes • check for cracks or other damage, ...

  • Page 91

    8-6 8 28 differential gear oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ 29 final gear oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ 30 cooling system • check coolant level and atv for coolant leakage, and correct if necessary. √ √ √ √ √ • re...

  • Page 92

    8-7 8 ebu23070 note: ● the air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal components of the brake master cylinders and calip...

  • Page 93

    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. Ebu27381 panel a to remove the panel pull upward on the areas shown. 1. Pane...

  • Page 94

    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) u3b460e0.Book page 9 friday, may 12, 2006 2:51 pm.

  • Page 95

    8-10 8 3. Remove the front carrier stays by removing the bolts. 4. Remove the quick fastener screws, and then pull the panel upward to remove it. 1. Carrier bolt (top) 1. Front carrier stay 1. Front carrier stay bolt u3b460e0.Book page 10 friday, may 12, 2006 2:51 pm.

  • Page 96

    8-11 8 to install the panel 1. Place the panel in the original position, and then install the quick fastener screws. 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...

  • Page 97

    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 as shown to remove it. To install the panel 1. Place the panel in the original position, and then install the quick faste...

  • Page 98

    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 as shown to remove it. Note: to ease removal of panel d, shift the drive select lever into the reverse position. 1...

  • Page 99

    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 u3b460e0.Book page 14 friday, may 12, 2006 2:51 pm.

  • Page 100

    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. Panel g to remove the panel remove the nut, bolts, and quick fastener, and then pull the panel downward while pushing the tab. 1. Panel f u3b460e0.Book page 15 friday, m...

  • Page 101

    8-16 8 to install the panel place the panel in the original position, and then in- stall the bolts, nut, and quick fastener. Panel h to remove the panel remove the nut, bolts, and quick fasteners, and then pull the panel downward while pushing the tab. 1. Panel g 2. Nut 3. Bolt 4. Quick fastener 5. ...

  • Page 102

    8-17 8 to install the panel place the panel in the original position, and then in- stall the bolts, nut, and quick fasteners. Panel i to remove the panel 1. Remove the seat. (see page 4-17.) 2. Remove the rear carrier by removing the bolts. 1. Panel h 2. Nut 3. Bolt 4. Quick fastener 5. Tab u3b460e0...

  • Page 103

    8-18 8 3. Remove the quick fasteners, and then push inward on the areas shown. 1. Carrier bolt (under the fenders) 1. Carrier bolt (upper) 1. Carrier bolt (lower) u3b460e0.Book page 18 friday, may 12, 2006 2:51 pm.

  • Page 104

    8-19 8 to install the panel 1. Place the panel in the original position, and then install the quick fasteners. 2. Install the rear carrier by installing the bolts and tightening them to the specified torques. 3. Install the seat. 1. Panel i 2. Quick fastener tightening torques: carrier bolt (upper):...

  • Page 105

    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 106

    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 107

    8-22 8 note: if a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4. Install the spark plug cap. Ebu27460 engine oil and oil ...

  • Page 108

    8-23 8 note: 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 pan...

  • Page 109

    8-24 8 note: 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. Note: 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 n...

  • Page 110

    8-25 8 9. Install panel g. 10. Install the engine oil drain bolt, and then tight- en it to the specified torque. 11. Add the specified amount of the recommend- ed engine oil, and then insert the dipstick com- pletely into the oil filler hole. Caution: ecb00300 ● in order to prevent clutch slippage (...

  • Page 111

    8-26 8 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 check the oil level and correct it if necessary. 14. Insta...

  • Page 112

    8-27 8 4. Install the oil level check bolt and oil filler bolt, and then tighten them to the specified torques. To change the final gear oil 1. Place the atv on a level surface. 2. Place an oil pan under the final gear case to collect the used oil. 3. Remove the final gear oil filler bolt, final gea...

  • Page 113

    8-28 8 caution: ecb00420 be sure no foreign material enters the final gear case. 6. Install the oil level check bolt and oil filler bolt, and then tighten them to the specified torques. 7. Check the final gear case for oil leakage. If oil is leaking, check for the cause. Ebu23421 differential gear o...

  • Page 114

    8-29 8 2. Remove the differential gear oil filler bolt, and then check the oil level in the differential gear case. Note: the oil level should be at the brim of the filler hole. 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct ...

  • Page 115

    8-30 8 5. Add the recommended differential gear oil to the brim of the filler hole as shown. Caution: 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 lea...

  • Page 116

    8-31 8 note: the coolant level must be checked on a cold en- gine since the level varies with engine tempera- ture. 2. Check the coolant level in the coolant reser- voir. Note: the coolant should be between the minimum and maximum level marks. 3. If the coolant is at or below the minimum level mark,...

  • Page 117

    8-32 8 caution: 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 w...

  • Page 118

    8-33 8 4. Remove panel b. (see page 8-8.) 5. Remove the radiator cap. 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. 1. Coolant drain bolt 1. Trough 1. Radiator cap u3b460e0.Book page 33 friday, may ...

  • Page 119

    8-34 8 8. After draining the coolant, thoroughly flush the cooling system with clean tap water. 9. Replace the coolant drain bolt washer if it is damaged, install the coolant drain bolt, and then tighten it to the specified torque. 10. Connect the coolant reservoir hose. 11. Pour the recommended coo...

  • Page 120

    8-35 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. 13. Loosen the water pump air bleed bolt, without removing it, to allow all of the air to escape from...

  • Page 121

    8-36 8 18. When coolant begins to flow out of the bolt hole, tighten the cylinder head air bleed bolt to the specified torque. 19. Start the engine and let it idle for ten minutes. 20. Rev the engine five times. 21. Pour the recommended coolant into the radia- tor until it is full. 22. Stop the engi...

  • Page 122

    8-37 8 the panels.) check the hoses periodically and, if dust or water collects in them, empty them and clean the air filter element and air filter case. 1. Remove panel c. (see page 8-8.) 2. Remove the air filter case cover by unhooking the holders. 1. Air filter case check hose 1. Air filter case ...

  • Page 123

    8-38 8 3. Remove the sponge material and the mesh from the air filter case. 4. Clean the mesh with solvent, and then wipe the solvent off. 5. 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-...

  • Page 124

    8-39 8 caution: ecb00440 do not twist the sponge material when squeez- ing it. 7. Check the sponge material and replace it if damaged. 8. Apply yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. Note: the sponge material should be wet but not drip- ping. 9. Ins...

  • Page 125

    8-40 8 caution: 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, op...

  • Page 126

    8-41 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 127

    8-42 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 128

    8-43 8 note: the engine is warm when it quickly responds to the throttle. 2. Remove panel c. (see page 8-8.) 3. Attach the tachometer to the spark plug lead. 4. Check the engine idling speed and, if neces- sary, adjust it to specification by turning the idle adjusting screw. To increase the engine i...

  • Page 129

    8-44 8 2. To increase the throttle cable free play, turn the adjusting bolt in direction (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b). 3. Tighten the locknut. Ebu24060 valve clearance the valve clearance changes with use, resulting in improper air-fuel mixt...

  • Page 130

    8-45 8 note: the wheels need to be removed to check the brake pads. (see page 8-62.) front brake rear brake ebu27842 checking the rear brake hose protec- tors the rear brake hoses protectors must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each b...

  • Page 131

    8-46 8 note: the wheels need to be removed to check the brake hose protectors. (see page 8-62.) 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 th...

  • Page 132

    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 133

    8-48 8 ebu27770 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. Each brake le- ver should have a free play of zero mm (zero in) as shown. If the free play is incor...

  • Page 134

    8-49 8 replacement of brake components requires professional knowledge. These procedures should be performed by a yamaha dealer. Ebu27780 adjusting the brake pedal free play and checking the brake pedal position the brake pedal free play must be adjusted and brake pedal position must be checked and,...

  • Page 135

    8-50 8 4. Tighten the locknut. 5. Install the panel. If the correct free play cannot be obtained, have a yamaha dealer adjust it. Note: when adjusting the rear brake pedal free play: ● be sure not to step on the brake pedal. ● make sure the rear brake lever and brake pedal do not move. Checking the ...

  • Page 136

    8-51 8 ● make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a yamaha dealer. Ebu24230 axle boots the axle boots must be checked for damage at the intervals specified...

  • Page 137

    8-52 8 warning ewb02130 inspect cables frequently and replace if dam- aged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could re- strict the operation of controls and lead to an accident or injury. Ebu24911 checking and lubricating t...

  • Page 138

    8-53 8 ebu24950 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. Note: to access the brake pedal pivot, remove panel h. (see page 8-8.) ebu24961 checking the wheel bearings the front a...

  • Page 139

    8-54 8 ebu25040 lubricating the upper and lower arm pivots the upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Ebu25050 lubricating the knuckle pivots the knuckle pivots must be lubricated at the inter- vals specified in t...

  • Page 140

    8-55 8 ebu25222 battery this model is equipped with a sealed-type (mf) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections. Caution: ecb00620 never attempt to remove the ba...

  • Page 141

    8-56 8 1. Place the battery in its compartment. 2. Make sure to properly connect the battery leads to the battery terminals. Caution: ecb00630 ● always keep the battery charged. Storing a discharged battery can cause permanent battery damage. ● to charge a sealed-type (mf) battery, a spe- cial const...

  • Page 142

    8-57 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. Caution: ecb00640 to prevent accidental short-circuiting, turn o...

  • Page 143

    8-58 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 144

    8-59 8 2. Remove the headlight bulb cover. 3. Disconnect the headlight coupler. 4. Unhook the headlight bulb holder, and then remove the defective bulb. 1. Cover at the rear of the headlight 1. Headlight bulb cover 1. Headlight coupler u3b460e0.Book page 59 friday, may 12, 2006 2:51 pm.

  • Page 145

    8-60 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 146

    8-61 8 caution: 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. Ebu25550 adjusting a headlight beam caution: ecb00690 it is advisable to have a yamaha dealer make this adjustment. To raise a he...

  • Page 147

    8-62 8 3. Remove the defective 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. Ebu25650 removing...

  • Page 148

    8-63 8 ebu25700 installing a wheel 1. Install the wheel and the nuts. Note: ● 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- wards the wheel. 2. Lower the atv t...

  • Page 149

    8-64 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 150

    8-65 8 ebu27690 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 151

    8-66 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 152

    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 153

    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 154

    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 155

    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 156

    10-2 10 engine oil: type: sae5w30 or sae10w30 or sae10w40 or sae15w40 or sae20w40 or sae20w50 recommended engine oil grade: api service se, sf, sg type or higher engine oil quantity: without oil filter cartridge replacement: 2.00 l (2.11 us qt) (1.76 imp.Qt) with oil filter cartridge replacement: 2....

  • Page 157

    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 158

    10-4 10 rear: 33.0 kpa (4.8 psi) (0.330 kgf/cm²) 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: dot 4 rear brake: type: dual disc brake operation:...

  • Page 159

    10-5 10 reverse indicator light: led coolant temperature warning light: led engine trouble warning light: led 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...

  • Page 160

    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 161

    11-2 11 the year of manufacture is listed in the vehicle identification number as shown in the illustration. Note: 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 lab...

  • Page 162

    11-3 11 1. Model label u3b460e0.Book page 3 friday, may 12, 2006 2:51 pm.

  • Page 163

    Index a accessories and loading ................................................ 6-6 accessories, auxiliary jack ........................................... 4-22 air filter element, cleaning ............................................ 8-36 axle boots ...................................................

  • Page 164

    Indicator lights and warning lights .................................. 4-2 instruments, lights and switches .................................... 5-7 k key identification number ............................................. 11-1 knuckle pivots, lubricating ...............................................

  • Page 165

    Wheel, installing ........................................................... 8-63 wheel, removing .......................................................... 8-62 u3b460e0.Book page 3 friday, may 12, 2006 2:51 pm.

  • Page 166

    Yamaha motor co., ltd. Printed on recycled paper printed in japan 2006.05-1.4 ×1 cr (e) u3b460e0.Book page 1 friday, may 12, 2006 2:51 pm.