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Yamaha KODIAK 450 Owner's Manual - Owner’S Manual

Other manuals for KODIAK 450: Owner's Manual

Summary of KODIAK 450

  • Page 1

    Dic183 yfm45kdxj/yfm45kpxj yfm45kdhj/yfm45kpaj yfm45kphj owner’s manual manuel du propriÉtaire manual del propietario bb5-f8199-60 read this manual carefully! It contains important safety information. Lire attentivement ce manuel! Il comprend d’importantes informations de sécurité. ¡lea este manual ...

  • Page 2

    Dic183 original instructions notice originale manual original printed in usa 2017.03-1.1×2 cr (e,f,s).

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Warning owner’s manual yfm45kdxj/yfm45kpxj yfm45kdhj/yfm45kpaj yfm45kphj this atv should not be ridden by anyone under 16 years of age. Bb5-f8199-60-e0 ubb560e0.Book page 1 tuesday, may 9, 2017 5:31 pm.

  • Page 4

    Ebu37040 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. En15997, ansi/svia 1-2010 general manager engineering division recreational vehicle business unit vehicle & solution business operations yamaha motor co., ltd. 23 january, 20...

  • Page 5

    En15997, ansi/svia 1-2010 general manager engineering division recreational vehicle business unit vehicle & solution business operations yamaha motor co., ltd. 23 january, 2017 we, yamaha motor co., ltd. 2500 shingai, iwata, japan, declare in sole responsibility, that the product (make, model) (if a...

  • Page 6

    Ebu17171 introduction ebu17293 congratulations on your purchase of the yamaha yfm45kdxj / yfm45kpxj / yfm45kdhj / yfm45kpaj / yfm45kphj. 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 o...

  • Page 7

    Ebu17331 important manual information ebu17343 failure to follow the warnings contained in this manual can result in serious in- jury or death. Particularly important information is distinguished in this manual by the following notations: * product and specifications are subject to change without no...

  • Page 8

    Ebu17351 important notice ebu17373 this atv is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this atv on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations before operating this atv. Ebu17411 yfm45kdxj / ...

  • Page 9

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

  • Page 10

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

  • Page 11

    Checking and lubricating the front and rear brake levers ..................................... 8-47 checking and lubricating the brake pedal ....................................................... 8-48 checking the wheel hub bearings............. 8-48 lubricating the drive shaft universal joint .......

  • Page 12

    1-1 1 ebu29681 location of the warning and specification labels ebu37160 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a re...

  • Page 13

    1-2 1 for europe 1 4 2 3 7 8 9,10 11 5 6 6 6 6 ubb560e0.Book page 2 friday, march 10, 2017 10:20 am.

  • Page 14

    1-3 1 37s-f817r-00 40 kg ( 88 lbs) 37s-f817r-10 80 kg ( 176 lbs) 35.0 kpa 0.35 kgf/cm² 5.0 psi 30.0 kpa 0.30 kgf/cm² 4.4 psi 1hp-f816m-m0 yamaha 1p0-f816p-20 1 2 3 4 ubb560e0.Book page 3 friday, march 10, 2017 10:20 am.

  • Page 15

    1-4 1 5880 n 600 kgf 1322 lbf 147 n 15 kgf 33 lbf 37s-f817s-00 1p0-f816r-00 bb5-f2259-20 7 5 6 ubb560e0.Book page 4 friday, march 10, 2017 10:20 am.

  • Page 16

    1-5 1 yamaha 1hp-f811r-00 yamaha motor co., ltd. 2500 shingai, iwata, japan yfm450fwbd 20.0 kw 295 kg 2017 bb5-f155a-00 yamaha motor co., ltd. 2500 shingai, iwata, japan yfm450fwb 20.0 kw 289 kg 2017 bj5-f155a-00 e10 b42-f817k-00 8 9 10 11 yfm45kdxj / yfm45kdhj 11 yfm45kpxj / yfm45kpaj / yfm45kphj u...

  • Page 17

    1-6 1 familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the owner’s manual. Always use an approved helmet and protective gear. Use from 16 years old. Operating this atv if you are under the age of 1...

  • Page 18: E10

    1-7 1 e10 **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi yamaha motor co., ltd. 2500 shingai, iwata, japan ****** *** kw *** kg **** 1 2 3 4 this pictogram shows trailer hitch tow weight limit. (combined weight of the trailer and all cargo in the trailer.) overloading can cause loss of ...

  • Page 19

    1-8 1 for oceania 1 2 4 3 6 8 9 5 7 7 7 7 ubb560e0.Book page 8 friday, march 10, 2017 10:20 am.

  • Page 20

    1-9 1 wait for the engine to return to normal idle speed before shifting. 2ud-f151e-00 recommended minimum : front rear : front rear : 35 kpa, (5.0 psi) : 30 kpa, (4.4 psi) : 32 kpa, (4.6 psi) : 27 kpa, (4.0 psi) never set tire pressure below minimum. It could cause the tire to dislodge from the rim...

  • Page 21

    1-10 1 bb5-f2259-20 7 8 6 ubb560e0.Book page 10 friday, march 10, 2017 10:20 am.

  • Page 22

    1-11 1 16 under 1p0-f816l-00 9 ubb560e0.Book page 11 friday, march 10, 2017 10:20 am.

  • Page 23

    2-1 2 ebu17432 safety information safety information ebu27255 an atv is not a toy and can be hazard- ous to operate. An atv handles differently from other vehicles, in- cluding motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding...

  • Page 24

    2-2 2  never operate at speeds too fast for your skills or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience.  never attempt wheelies, jumps, or other stunts.  always inspect your atv each time you use it to make sure...

  • Page 25

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

  • Page 26

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

  • Page 27

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

  • Page 28

    2-6 2 gerous loss of lights or engine power. Also, the battery tends to discharge more quickly if elec- trical accessories are added. Warning ewb00073 avoid carbon monoxide poisoning all engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, ...

  • Page 29

    3-1 3 ebu17681 description ebu17691 left view ebu17701 right view 1. Radiator cap 2. Air filter case 3. Battery 4. Fuses 5. Tail/brake light 6. Engine oil filler cap 7. Oil filter cartridge 8. Coolant reservoir 9. V-belt cooling duct check hose 1 2 3 4 5 9 7 8 6 1. Spark arrester 2. Storage compartm...

  • Page 30

    3-2 3 ebu17714 controls and instruments tip the atv you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Horn switch 4. Drive select lever 5. Display unit 6. Front brake fluid reservoir 7. On-command four-wheel-drive switch “2wd”/...

  • Page 31

    4-1 4 ebu17739 instrument and control functions ebu29912 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. “...

  • Page 32

    4-2 4 ebu26697 indicator lights and warning lights ebu17861 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu17831 reverse indicator light “ ” this indicator light comes on when the transmis- sion is in the reverse position. Ebu17971 pa...

  • Page 33

    4-3 4 notice ecb02400  the engine may overheat if the atv is over- loaded. In this case, reduce the load to spec- ification.  the engine may also overheat if mud or dirt has accumulated on the radiator (i.E., after riding in wet terrain). In this case, have a yamaha dealer clean the radiator.  st...

  • Page 34

    4-4 4  if the steering load is too heavy (i.E., excessive steering use when the atv is traveling at a slow speed), the power assist is reduced to protect the eps motor from overheating. Ebu17954 on-command four-wheel-drive indicator light “ ” this indicator light comes on when the on-com- mand four...

  • Page 35

    4-5 4 fuel gauge the fuel gauge indicates the amount of fuel in the fuel tank. The display segments of the fuel gauge disappear from “f” (full) towards “e” (empty) as the fuel level decreases. When the last segment starts flashing, refuel as soon as possible. Tip this fuel gauge is equipped with a s...

  • Page 36

    4-6 4 tip  the odometer will lock at 99999.  the tripmeter will reset and continue counting after 9999.9 is reached. Service tripmeter the service tripmeter shows the distance traveled since it was reset at the last maintenance. To reset the service tripmeter, push the select but- ton “sel” for on...

  • Page 37

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

  • Page 38

    4-8 4 handle differently. This could distract the oper- ator and increase the risk of losing control and of causing an accident. This atv is equipped with a switch to change from two-wheel drive to four-wheel drive and vice ver- sa. Select the appropriate drive according to the terrain and the condi...

  • Page 39

    4-9 4 before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. Ebu18324 speed limiter your atv is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening,...

  • Page 40

    4-10 4 3. Tighten the locknut. Ebu18392 front brake lever the front brake lever is located on the right han- dlebar. To apply the front brake, pull the brake le- ver toward the handlebar grip. Ebu18443 brake pedal and rear brake lever the brake pedal is located on the right side of the atv and the r...

  • Page 41

    4-11 4 ebu18613 drive select lever the drive select lever is used to shift the transmis- sion into the low-range, high-range, neutral, re- verse and park positions. See page 6-2 for drive select lever operation. Ebu18721 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. Ebu187...

  • Page 42: E10

    4-12 4 of sparks, open flames, or other sources of ignition such as the pilot lights of water heat- ers and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole. Stop filling when the fuel reaches the bottom of the filler ...

  • Page 43

    4-13 4 3. Wipe up any spilled fuel immediately. Notice: immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. [ecb00982] 4. Turn the fuel tank cap fully clockwise to make sure it is securely closed. Warning ewb02532 gasoline is...

  • Page 44

    4-14 4 to install the seat insert the projections on the front of the seat into the seat holders, and then push down on the seat at the rear to lock it in place. Make sure that the seat is securely fitted. Ebu37060 storage compartment notice ecb00131 do not store metal or sharply edged objects, like...

  • Page 45

    4-15 4  do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment.  do not exceed the maximum load of 240.0 kg (530 lb) for the atv. Ebu18963 front carrier  do not exceed the load limit of 40.0 kg (88 lb) for the front carrier.  do not exceed the maximum load of 240.0 kg (530 lb)...

  • Page 46

    4-16 4 align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. Tip a special wrench can be obtained at a yamaha dealer to make this adjustment. 1. Spring preload adjusting ring 2. Position indicator 1 2 3 4 5 (a) (b) 1 2 1. Special wrench spring preload s...

  • Page 47

    4-17 4 ebu19184 auxiliary dc jack the auxiliary dc jack is located at the front right side of the atv. The auxiliary dc jack can be used for suitable work lights, radios, etc. The auxiliary dc jack should only be used when the engine is running and the light switch is set to “off”. 1. Set the light ...

  • Page 48

    5-1 5 ebu19203 pre-operation checks ebu19226 inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual. Warning ewb00482 failure to inspect or maintain the v...

  • Page 49

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

  • Page 50

    5-3 5 ebu19542 fuel make sure that there is sufficient fuel in the tank. (see page 4-11.) ebu19561 engine oil make sure that the engine oil is at the specified level. Add oil as necessary. (see page 8-17.) ebu19591 final gear oil make sure that the final gear oil is at the specified level. Add oil a...

  • Page 51

    5-4 5 brake fluid leakage (front brake) check to see if any brake fluid is leaking out of the hose, joint or brake fluid reservoir of the front brake. Apply the brake firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake ...

  • Page 52

    5-5 5 tire pressure gauge a low-pressure tire gauge is included as standard equipment with your vehicle. (see page 8-2.) when using the tire pressure gauge, make two measurements and use the second reading as grit in the gauge or tire valve could have caused the first reading to be incorrect. Tire w...

  • Page 53

    5-6 5 aftermarket tires and rims the tires and rims that came with your atv were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Ebu19841 chassis fasteners make su...

  • Page 54

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

  • Page 55

    6-2 6 on. If the indicator light does not come on, have a yamaha dealer check the electrical circuit. 3. Apply the rear brake lever or brake pedal. 4. Completely close the throttle lever, then push the start switch to crank the engine with the starter. Release the start switch when the en- gine has ...

  • Page 56

    6-3 6 3. Release the brake pedal, and then open the throttle lever gradually. Shifting: neutral to reverse and reverse to park warning ewb00721 improper operation in reverse could make you hit an obstacle or even a person behind you, resulting in serious injury. When you shift into reverse, make sur...

  • Page 57

    6-4 6 tip  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 behin...

  • Page 58

    6-5 6 ebu29901 parking on a slope warning ewb00861 avoid parking on hills or other inclines. Parking on a hill or other incline could cause the atv to roll out of control, increasing the chance of an accident. If you must park on an incline, place the atv transversely across the incline, stop the en...

  • Page 59

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

  • Page 60

    6-7 6  never exceed the weight limits shown. An over- loaded atv can be unstable.  do not exceed the maximum tongue weight. You can measure tongue weight with a bath- room scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Ad- just the load in the trailer, if...

  • Page 61

    7-1 7 ebu21142 riding your atv ubb560e0.Book page 1 friday, march 10, 2017 10:20 am.

  • Page 62

    7-2 7 ebu37070 getting to know your atv this atv is for recreation and utility use. This sec- tion, riding your atv, provides general atv riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your at...

  • Page 63

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

  • Page 64

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

  • Page 65

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

  • Page 66

    7-6 7 fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the atv. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (see page 4-9.)...

  • Page 67

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

  • Page 68

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

  • Page 69

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

  • Page 70

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

  • Page 71

    7-11 7 terrain could cause loss of traction or atv con- trol, which could result in an accident, includ- ing an overturn. [ewb01542] when riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the atv. Do not use the flag pole bracket as a trailer hitch...

  • Page 72

    7-12 7 select a large, flat, unpaved area to become famil- iar with your atv. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Shift to t...

  • Page 73

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

  • Page 74

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

  • Page 75

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

  • Page 76

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

  • Page 77

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

  • Page 78

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

  • Page 79

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

  • Page 80

    7-20 7 riding over rough terrain warning ewb01652 riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as lar- ge rocks or fallen trees. When you go over obstacles, always ...

  • Page 81

    7-21 7 accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the atv as loss of control and damage to the atv may result. Sliding and skidding warning ewb01663 skidding or sliding improperly may cause you to lose control of this atv. You may also regain tra...

  • Page 82

    7-22 7 with practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfa...

  • Page 83

    7-23 7  if your atv is traversing a sloping surface: be sure to ride with your weight positioned to- wards the uphill side of the atv to maintain proper balance. If the atv starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the atv is ...

  • Page 84

    8-1 8 ebu28788 periodic maintenance and adjustment ebu21676 periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most effi- cient condition possible. Safety is an obligation of the vehicle owner and operator. The most impor- tant points of vehicle inspection, adj...

  • Page 85

    8-2 8  for odometer or hour meter-equipped vehicles, follow the month maintenance interval if the atv isn’t ridden for the stated mileage or engine op- erating hours.  items marked with an asterisk should be per- formed by a yamaha dealer as they require spe- cial tools, data and technical skills....

  • Page 86

    8-3 8 ebu36871 periodic maintenance chart: emission control system no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 240 (150) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 * fuel line • check fuel hoses for cracks or other da...

  • Page 87

    8-4 8 ebu36891 periodic maintenance chart: general maintenance and lubrication no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 240 (150) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 air filter element • clean and replace if...

  • Page 88

    8-5 8 8 * tires • check tread depth and for damage, and replace if necessary. • check air pressure and balance, and correct if necessary. √ √ √ √ 9 * wheel hub bearings • check for looseness or damage, and replace if necessary. √ √ √ √ 10 * v-belt • check for wear, cracks or other damage, and re- pl...

  • Page 89

    8-6 8 18 * engine mount • check for cracks or other damage, and replace if necessary. √ √ √ 19 * axle boots • check for cracks or other damage, and replace if necessary. √ √ √ √ √ 20 engine oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ √ √ 21 engine oil filter car- tridg...

  • Page 90

    8-7 8 ebu28392 tip  some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle.  hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal components...

  • Page 91

    8-8 8 ebu23091 removing and installing panels the panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel a 2. Panel b 2 1 1. Panel c 2. Panel d 3. Panel e 1. Panel f 1 3 2 ...

  • Page 92

    8-9 8 ebu27605 panel a when removing or installing panel a, the fuel tank cap must be removed. Notice: make sure that no foreign material enters the fuel tank. [ecb01052] to remove the panel 1. Remove the seat. (see page 4-13.) 2. Remove the bolts and quick fasteners. 3. Remove the fuel tank cap, an...

  • Page 93

    8-10 8 4. Install the fuel tank cap. To install the panel 1. Remove the fuel tank cap. 2. Place the panel over the fuel tank filler tube, and then install the fuel tank cap. 3. Install the bolts and quick fasteners. 4. Install the seat. Panels b and c when removing or installing panel c, the drive s...

  • Page 94

    8-11 8 to install a panel 1. Push the panel to secure the tabs. 2. Install panel a. Panel d to remove the panel remove the bolts, and then take the panel off. To install the panel place the panel in the original position, and then install the bolts. Panel e to remove the panel pull outward on the ar...

  • Page 95

    8-12 8 to install the panel insert the right side of the panel into position, and then press the projections into place. Panel f to remove the panel 1. Remove panels b and c. 2. Remove the cover.  for yfm45kpxj / yfm45kpaj / yfm45kphj: remove the handlebar- mounted light cover. (see page 8-57.)  f...

  • Page 96

    8-13 8 yfm45kdxj / yfm45kdhj 3. Remove the carrier top bolts. 4. Remove the carrier bolts under the fenders, and then take the carrier off. 1. Handlebar cover 1 1. Carrier bolt (top) 2. Panel f 1 1 1 2 ubb560e0.Book page 13 friday, march 10, 2017 10:20 am.

  • Page 97

    8-14 8 5. Remove the quick fasteners. 6. Lift up the panel and disconnect the coupler. 1. Carrier bolt (under the fenders) 1. Carrier bolt (under the fenders) 1 1 1. Quick fastener 1. Coupler 1 1 ubb560e0.Book page 14 friday, march 10, 2017 10:20 am.

  • Page 98

    8-15 8 to install the panel 1. Connect the coupler, and then place the pan- el in the original position. 2. Install the quick fasteners. 3. Place the carrier in the original position, and then install the carrier bolts under the fenders. 4. Install the carrier top bolts, and then tighten all bolts t...

  • Page 99

    8-16 8 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medi- um-to-light tan (the ideal color when the atv is ridden normally). Tip if the ...

  • Page 100

    8-17 8 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. 3. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification. To install the spark plug 1. Clean the surface of the spark plug g...

  • Page 101

    8-18 8 to check the engine oil level 1. Place the atv on a level surface. 2. Remove panel e. (see page 8-8.) 3. Check the engine oil level on a cold engine. Tip if the engine was started before checking the oil level, warm up the engine, and then wait at least ten minutes until the oil settles for a...

  • Page 102

    8-19 8 raise it to the correct level. Notice: be sure the engine oil is at the correct level, other- wise engine damage may result. [ecb00852] 7. Check the filler cap o-ring for damage, and replace it if necessary. 8. Install the engine oil filler cap and the panel. To change the engine oil (and rep...

  • Page 103

    8-20 8 tip an oil filter wrench is available at a nearby yamaha dealer. 8. Apply a thin coat of engine oil to the o-ring of the new oil filter cartridge. Tip make sure that the o-ring is properly seated. 9. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to the ...

  • Page 104

    8-21 8 10. Install panels d and c. 11. Install the engine oil drain bolt and its new gasket, and then tighten the bolt to the spec- ified torque. 12. Refill with the specified amount of the recom- mended engine oil. Tip be sure to wipe off spilled oil on any parts after the engine and exhaust system...

  • Page 105

    8-22 8 13. Check the engine oil filler cap o-ring for dam- age, and then install the filler cap. 14. Start the engine and let it idle for several mi- nutes while checking for oil leakage. If any oil leakage is found, immediately turn the engine off and check for the cause. 15. Turn the engine off, w...

  • Page 106

    8-23 8 to change the final gear oil 1. Place the atv on a level surface. 2. Remove the final gear case guard by remov- ing the bolts. 3. Place an oil pan under the final gear case to collect the used oil. 4. Remove the final gear oil filler bolt, the final gear oil drain bolt and their gasket to dra...

  • Page 107

    8-24 8 tip if the recommended oil is not available, sae 80w- 90 api gl-5 hypoid gear oil may be used instead. However, when using this oil, noise from the final gear case may occur when applying the rear brake. 7. Check the oil filler bolt gasket for damage, and replace it if necessary. 8. Install t...

  • Page 108

    8-25 8 1. Place the atv on a level surface. 2. Place an oil pan under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt, the differential gear oil drain bolt and their gasket to drain the oil from the differential gear case. 4. Install the drain bolt...

  • Page 109

    8-26 8 tip  do not exceed the specified differential gear oil quantity when filling. Overfilling will cause the oil to seep out of the breather hose during and af- ter riding.  the differential gear case capacity is greater than the recommended oil quantity, therefore the oil level cannot be accur...

  • Page 110

    8-27 8 3. If the coolant is at or below the minimum level mark, remove panel c to access the coolant reservoir. (see page 8-8.) 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: if coolant i...

  • Page 111

    8-28 8 tip  the radiator fan is automatically switched on or off according to the coolant temperature in the radiator.  if the engine overheats, see page 8-65 for fur- ther instructions. Ebu37130 to change the coolant warning ewb01891 wait for the engine and radiator to cool before removing the ra...

  • Page 112

    8-29 8 6. Remove the coolant reservoir cap. 7. Disconnect the coolant reservoir hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 8. After draining the coolant, thoroughly flush the cooling system with clean tap water. 9. Install the coolant drain bolt and it...

  • Page 113

    8-30 8 11. Pour the recommended coolant into the res- ervoir to the maximum level mark, and then install the reservoir cap. Notice: mix anti- freeze with distilled water only. However, if distilled water is not available, soft water may be used for refilling. Do not use hard water or salt water sinc...

  • Page 114

    8-31 8  service the air filter more frequently if you often ride in wet or dusty areas.  there is a check hose at the bottom of the air fil- ter case. If dust or water collects in this hose, empty the hose and clean the air filter case and air filter elements. 1. Place the atv on a level surface. ...

  • Page 115

    8-32 8 5. Pull off the lock plate from the main air filter assembly, and then remove the air filter ele- ment (sponge material) from the frame. 6. Wash the air filter elements gently but thor- oughly with yamalube air filter cleaner, or a dedicated parts cleaning solvent. Warning! Always use parts c...

  • Page 116

    8-33 8 7. Squeeze out the excess moisture, and let dry. Notice: do not twist the sponge material when squeezing it. [ecb00442] 8. Check the air filter elements (sponge material) for damage, replace if necessary. 9. Apply yamalube foam air filter oil (or equivalent) to the air filter elements. Tip th...

  • Page 117

    8-34 8 2. Remove the tailpipe by pulling it out of the muffler, and then remove the gasket. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Check the gasket for damage, and rep...

  • Page 118

    8-35 8 warning ewb02341 do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire. Always let the exhaust system cool prior to touching exhaust components. Ebu23921 v-belt coo...

  • Page 119

    8-36 8 ebu29703 adjusting the throttle lever free play the throttle lever free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The throttle lever free play should measure 3.0–5.0 mm (0.12–0.20 in) as shown. Periodically...

  • Page 120

    8-37 8 ebu29602 brakes replacement of brake components requires pro- fessional knowledge. Brake service should be performed by a yamaha dealer. Warning ewb02572 operating with improperly serviced or adjust- ed brakes could lead to a loss in braking ability and an accident. Ebu28414 checking the fron...

  • Page 121

    8-38 8 ebu30321 rear brake friction plates the rear brake friction plates must be checked and, if necessary, replaced by a yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Ebu29844 checking the brake fluid level before riding, check that the brake fluid is ...

  • Page 122

    8-39 8  clean the filler cap before removing. Use only dot 4 brake fluid from a sealed contain- er.  use only the specified brake fluid; otherwise, the rubber seals may deteriorate, causing leakage.  refill with the same type of brake fluid. Add- ing a brake fluid other than dot 4 may result in a...

  • Page 123

    8-40 8 ebu30346 adjusting the rear brake lever and brake pedal the rear brake lever free play, brake pedal free play, and the brake pedal height must be checked and adjusted at the intervals specified in the peri- odic maintenance chart. Adjusting the brake lever free play the brake lever free play ...

  • Page 124

    8-41 8 tip if the specified brake lever free play could be ob- tained as described above, skip steps 3-8. 3. Fully turn the adjusting bolt in direction (a) to loosen the brake cable. 4. Slide the rubber cover back. 5. Loosen the brake cable adjuster locknut. 6. To increase the brake lever free play,...

  • Page 125

    8-42 8 1. Remove the footboard by removing the quick fasteners, bolts, and nuts. 2. Loosen the locknut. 1. Distance between brake pedal and footboard bracket 1 1. Footboard 2. Quick fastener 3. Bolt and nut 4. Bolt 4 2 3 3 1 2 ubb560e0.Book page 42 friday, march 10, 2017 10:20 am.

  • Page 126

    8-43 8 3. Turn the adjusting bolt in or out until the brake pedal height is within the specified limits. 4. Tighten the locknut. 5. Install the footboard by installing the quick fasteners, bolts, and nuts, and then tighten the bolts to the specified torques. Tip tighten the footboard bolts in the or...

  • Page 127

    8-44 8 adjusting the brake pedal free play the brake pedal free play should measure 20.0 mm (0.79 in). If the free play is incorrect, adjust it as follows. Tip the brake lever free play and brake pedal height must be adjusted before adjusting the brake pedal free play. 1. Loosen the locknut. Tighten...

  • Page 128

    8-45 8 2. To increase the brake pedal free play, turn the brake pedal free play adjusting nut in direc- tion (a). To decrease the brake pedal free play, turn the adjusting nut in direction (b). 3. Tighten the locknut. Ebu24231 axle boots the axle boots must be checked for damage at the intervals spe...

  • Page 129

    8-46 8 ebu29882 brake light switches the brake light, which is activated by the brake pedal and brake levers, should come on just be- fore braking takes effect. The rear brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a yama...

  • Page 130

    8-47 8 do not work smoothly, you could be unable to control the atv, which could lead to an accident or collision. Ebu28712 checking and lubricating the front and rear brake levers the operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lub...

  • Page 131

    8-48 8 ebu28872 checking and lubricating the brake pedal the operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. Ebu24964 checking the wheel hub bearings the front and rear wheel hub bearings must be checked at the intervals specifi...

  • Page 132

    8-49 8 tip for parts equipped with a grease nipple, use a grease gun. Ebu25023 checking the stabilizer bushes the stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a yamaha dealer replace the stabilizer bush- es ...

  • Page 133

    8-50 8 tip for parts equipped with a grease nipple, use a grease gun. Ebu25095 lubricating the steering shaft the steering shaft must be lubricated by a yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart. Yfm45kdxj / yfm45kdhj yfm45kpxj / yfm45kpaj / yfm45kp...

  • Page 134

    8-51 8 tip for parts equipped with a grease nipple, use a grease gun. Ebu2918b battery this model is equipped with a 12-volt vrla (valve-regulated lead-acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and tig...

  • Page 135

    8-52 8 3. Disconnect the negative battery lead first, then the positive battery lead by removing their bolt. Notice: when removing the bat- tery, the main switch must be off, and the negative lead must be disconnected be- fore the positive lead. [ecb01002] 4. Pull the battery out of its compartment....

  • Page 136

    8-53 8 notice ecb00942  always keep the battery charged. Storing the battery in a discharged state for an extended period of time will cause permanent battery damage.  do not store the battery in an excessively cold or warm place [below freezing or above 30 °c (90 °f)]. To install the battery 1. P...

  • Page 137

    8-54 8 ebu30804 replacing a fuse for non-eps models 1. Fuel injection system spare fuse 2. Fuel injection system fuse 3. Main fuse 4. Fuse box 1 2 3 4 1. Auxiliary dc jack fuse 2. Four-wheel-drive motor fuse 3. Ignition fuse 4. Radiator fan motor fuse 5. Signaling system fuse 6. Headlight fuse 7. Sp...

  • Page 138

    8-55 8 for eps models if an electrical problem is suspected, check the fuse and replace it if necessary as follows. Notice ecb00641 to prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 1. Turn off all electrical systems. (see page 4-1.) 1. Fuel injectio...

  • Page 139

    8-56 8 2. Remove the seat. (see page 4-13.) 3. Remove the blown fuse, and then install a new fuse of the specified amperage. Warning! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in place of the proper fuse. An improper fuse or a substitute object can cause damage...

  • Page 140

    8-57 8 ebu34223 replacing a headlight bulb if a headlight bulb burns out, replace it with the specified bulb as follows. Left and right headlight bulbs 1. Remove the cover at the rear of the headlight by pulling it off. 2. Remove the bulb cover by pulling it off. 3. Remove the socket by pushing it i...

  • Page 141

    8-58 8 4. Remove the burnt-out bulb. 5. Place a new bulb into position. Notice: do not touch the glass part of the bulb. Oil from your fingers or other contamination will adversely affect the transparency of the glass, luminosity of the bulb, and bulb life. Thoroughly clean off any dirt and fin- ger...

  • Page 142

    8-59 8 3. Remove the socket by pushing it in and turn- ing it counterclockwise. 4. Remove the burnt-out bulb. 5. Place a new bulb into position. Notice: do not touch the glass part of the bulb. Oil from your fingers or other contamination will adversely affect the transparency of the glass, luminosi...

  • Page 143

    8-60 8 8. Install the handlebar-mounted light cover as shown, and then install the quick fasteners. 9. Adjust the handlebar-mounted light beam if necessary. Ebu25553 adjusting a headlight beam notice ecb00691 it is advisable to have a yamaha dealer make this adjustment. To raise a headlight beam, tu...

  • Page 144

    8-61 8 ebu25614 replacing the tail/brake light bulb if the tail/brake light bulb burns out, replace it as follows. 1. Remove the tail/brake light bulb holder (to- gether with the bulb) by turning it counter- clockwise. 2. Remove the burnt-out bulb by pushing it in and turning it counterclockwise. 3....

  • Page 145

    8-62 8 3. Elevate the atv and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. Ebu36243 installing a wheel 1. Install the wheel with the arrow mark pointing in the forward rotating direction of the wheel, and then install the wheel nuts. Tip for yfm45kd...

  • Page 146

    8-63 8 2. Lower the atv to the ground. 3. Tighten the wheel nuts to the specified torques. Ebu25741 troubleshooting although yamaha atvs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, fo...

  • Page 147

    8-64 8 ebu27695 troubleshooting charts starting problems or poor engine performance check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Check the battery. Supply fuel. The engine does not start. Check the battery. Operate the electric starter. 4. Compression there ...

  • Page 148

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

  • Page 149

    9-1 9 ebu25861 cleaning and storage ebu25882 cleaning frequent, thorough cleaning of your atv will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the atv: a. Block off the end of the exhaust pipe to prevent w...

  • Page 150

    9-2 9 ebu27264 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a porous cover. Notice: storing the atv in a poorly ven- tilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust...

  • Page 151

    9-3 9 8. Remove the battery and fully charge it. (see page 8-51.) ubb560e0.Book page 3 friday, march 10, 2017 10:20 am.

  • Page 152

    10-1 10 ebu25962 specifications dimensions: overall length: 2035 mm (80.1 in) overall width: 1180 mm (46.5 in) overall height: 1160 mm (45.7 in) seat height: 855 mm (33.7 in) wheelbase: 1240 mm (48.8 in) ground clearance: 245 mm (9.6 in) minimum turning radius: 3200 mm (126 in) weight: curb weight: ...

  • Page 153

    10-2 10 compression ratio: 10.0 : 1 starting system: electric starter lubrication system: wet sump engine oil: recommended brand: yamalube type: sae 5w-30, 10w-30, 10w-40, 15w-40, 20w-40 or 20w- 50 recommended engine oil grade: api service sg type or higher, jaso standard ma engine oil quantity: wit...

  • Page 154

    10-3 10 fuel injection: throttle body: id mark: bb51 00 spark plug (s): manufacturer/model: ngk/dr7ea spark plug gap: 0.6–0.7 mm (0.024–0.028 in) clutch: clutch type: wet, centrifugal automatic transmission: secondary reduction system: shaft drive secondary reduction ratio: 39/24 × 24/18 × 33/9 (7.9...

  • Page 155

    10-4 10 tire air pressure (measured on cold tires): recommended: front: 35.0 kpa (0.350 kgf/cm², 5.0 psi) rear: 30.0 kpa (0.300 kgf/cm², 4.4 psi) minimum: front: 32.0 kpa (0.320 kgf/cm², 4.6 psi) rear: 27.0 kpa (0.270 kgf/cm², 4.0 psi) front wheel: wheel type: cast wheel (yfm45kpaj) panel wheel (yfm...

  • Page 156

    10-5 10 headlight(s): bulb type: krypton bulb handlebar-mounted light: bulb type: halogen bulb (yfm45kpaj, yfm45kphj, yfm45kpxj) bulb voltage, wattage × quantity: headlight: 12 v, 30.0/30.0 w × 2 handlebar-mounted light: 12 v, 35.0/36.5 w × 1 (yfm45kpaj, yfm45kphj, yfm45kpxj) tail/brake light: 12 v,...

  • Page 157

    10-6 10 work room, the other sources of noise, etc. I.E. The number of machines and other adjacent process- es, and the length of time for which an operator is exposed to the noise. Also the permissible expo- sure level can vary from country. This information, however, will enable the user of the ma...

  • Page 158

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

  • Page 159

    11-2 11 1. Model label 1 ubb560e0.Book page 2 friday, march 10, 2017 10:20 am.

  • Page 160

    12-1 12 index a accessories and loading ................................................6-5 accessories, auxiliary jack ...........................................4-17 air filter, cleaning .........................................................8-30 axle boots .........................................

  • Page 161

    12-2 12 m main switch .................................................................... 4-1 maintenance and lubrication chart ................................ 8-4 maintenance chart, emission control system ................ 8-3 model label .............................................................

  • Page 162

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