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Yamaha WOLVERINE 450 YFM45FXX Owner's Manual - Owner’S Manual

Summary of WOLVERINE 450 YFM45FXX

  • Page 1

    Yfm45fxw owner’s manual manuel du propriÉtaire manual del propietario 3c2-f8199-61 dic183.

  • Page 2

    Printed in usa 2006.07-0.3 ×1 cr (e,f,s) yamaha motor co., ltd. Dic183.

  • Page 3: Owner’S Manual

    Owner’s manual yfm45fxw 3c2-f8199-61-e0 u3c261e0.Book page 1 thursday, june 29, 2006 4:15 pm.

  • Page 4

    U3c261e0.Book page 2 thursday, june 29, 2006 4:15 pm.

  • Page 5

    Ebu17170 introduction ebu17320 congratulations on your purchase of the yamaha yfm45fxw. 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

    Operation .................................................. 6-1 starting a cold engine ................................ 6-1 starting a warm engine .............................. 6-3 operating the drive select lever and driving in reverse ...................................... 6-3 engine break-in .....

  • Page 10

    Adjusting the rear brake lever free play and checking the brake pedal position ... 8-40 axle boots ................................................ 8-42 brake light switches ................................. 8-43 checking and lubricating the cables ........ 8-43 checking and lubricating the front an...

  • Page 11

    1-1 1 ebu17430 safety information ebu17534 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 hill. If you stall or roll backwards, follow the spe- cial procedure for braking described in this man- ual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the atv around and remount, following the procedure described in this manual. ● always check for obstacles befo...

  • Page 14

    1-4 1 ● when transporting the atv in another vehi- cle, be sure it is kept upright and that the fuel cock is in the “off” position. Otherwise, fuel may leak out of the carburetor or fuel tank. ● gasoline is poisonous. If you should swal- low some gasoline or inhale a lot of gasoline vapor, or get so...

  • Page 15

    2-1 2 ebu17660 location of the warning and specification labels u3c261e0.Book page 1 thursday, june 29, 2006 4:15 pm.

  • Page 16

    2-2 2 ebu17670 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a replace- ment label from your yamaha dealer. U3c261e0.Book p...

  • Page 17

    2-3 2 u3c261e0.Book page 3 thursday, june 29, 2006 4:15 pm.

  • Page 18

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Front shock absorber assembly spring preload adjusting ring 2. Fuel cock 3. Air filter case 4. Fuses 5. Storage compartment and tool kit 6. Seat lock lever 7. Rear shock absorber assembly spring preload adjusting ring 8. Engine oil...

  • Page 19

    3-2 3 ebu17712 controls and instruments note: the atv you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Left handlebar switches 3. Starter (choke) 4. Drive select lever 5. Main switch 6. Speedometer unit 7. Fuel tank cap 8. Front brake fluid reservo...

  • Page 20

    4-1 4 ebu17731 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 21

    4-2 4 ebu17813 indicator lights and warning light ebu17840 reverse indicator light “ ” this indicator light comes on when the transmis- sion is in the reverse position. Note: if the indicator light flashes or the speedometer does not show the speed while riding, have a yamaha dealer check the speed ...

  • Page 22

    4-3 4 note: due to the synchronizing mechanism in the differ- ential gear case, the indicator may not come on un- til the atv starts moving. Ebu17970 park indicator light “ ” this indicator light comes on when the transmis- sion is in the park position. Ebu26362 speedometer unit the speedometer unit...

  • Page 23

    4-4 4 ebu18061 handlebar switches ebu18080 engine stop switch “ / ” set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run ...

  • Page 24

    4-5 4 ebu28220 on-command four-wheel-drive switch “2wd”/“4wd” this atv is equipped with a switch to change from two-wheel drive to four-wheel drive and vice-versa. Select the appropriate drive according to the ter- rain and the conditions. ● “2wd” (two-wheel drive): power is supplied to the rear whe...

  • Page 25

    4-6 4 ebu18280 throttle lever once the engine is running, movement of the throt- tle lever will increase the engine speed. Regulate the speed of the atv by varying the throttle position. Because the throttle is spring- loaded, the atv will decelerate, and the engine will return to an idle any time t...

  • Page 26

    4-7 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 throttle...

  • Page 27

    4-8 4 ebu18621 drive select lever the drive select lever is used to shift your atv into the forward, neutral, reverse and park positions. See the “operating the drive select lever and driv- ing in reverse” section on page 6-3 for the drive se- lect lever operation. Ebu18720 fuel tank cap remove the ...

  • Page 28

    4-9 4 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 1. Fuel level 2. Fuel tank filler tube recommended fuel: unleaded gasoline only for europe: regular unleaded gasoline only with a research octane nu...

  • Page 29

    4-10 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 30

    4-11 4 on with the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding. Res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to thi...

  • Page 31

    4-12 4 move the starter (choke) in direction (b) to turn off the starter (choke). See the “starting a cold engine” section on page 6-1 for proper operation. Ebu26981 seat to remove the seat push the seat lock lever backward and pull up the seat at the rear. 1. Starter (choke) “ ” 1. Seat 1. Seat loc...

  • Page 32

    4-13 4 to install the seat fit the slot in the seat onto the projection on the front cowling, insert the projections on the front of the seat into the seat holders, and then push on the seat at the rear. Note: make sure that the seat is securely fitted. Ebu26551 storage compartment the storage compa...

  • Page 33

    4-14 4 ● do not exceed the maximum load of 100.0 kg (220 lb) for the atv. Note: drain plugs are fitted at the bottom of the storage compartment. If any water collects in the storage compartment, remove the drain plugs, drain the water, and then install the drain plugs. Ebu18990 adjusting the front s...

  • Page 34

    4-15 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. Ebu19020 adjusting the rear shock absorber as- sembly the spring preload can be adju...

  • Page 35

    4-16 4 note: a special wrench can be obtained at a yamaha dealer to make this adjustment. 1. Spring preload adjusting ring 2. Position indicator 1. Special wrench spring preload setting: minimum (soft): 1 standard: 2 maximum (hard): 5 u3c261e0.Book page 16 thursday, june 29, 2006 4:15 pm.

  • Page 36

    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 37

    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 38

    5-3 5 ebu19540 fuel make sure that there is sufficient fuel in the tank. (see page 4-9.) 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, esp...

  • Page 39

    5-4 5 ebu19731 front and rear brakes brake levers and brake pedal ● check that there is no free play in the front brake lever. If there is free play, have a yamaha dealer check the brake system. ● check for correct free play in the rear brake le- ver. If the free play is incorrect, adjust it. (see p...

  • Page 40

    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. Ebu19811 tires warning ewb00591 use of improper tires on this atv, or operation of this atv with improper or u...

  • Page 41

    5-6 5 • 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 pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully. Ebu19820...

  • Page 42

    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 43

    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 44

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

  • Page 45

    6-3 6 note: the engine is warm when it responds normally to the throttle with the starter (choke) turned off. Ebu20291 starting a warm engine follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start t...

  • Page 46

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

  • Page 47

    6-5 6 ebu20682 engine break-in note: ● for atvs equipped with an odometer or an hour meter, follow the figures given in km (mi) or the figures given in hours. ● for atvs not equipped with an odometer or hour meter, follow the figures given in hours. There is never a more important period in the life...

  • Page 48

    6-6 6 incline, place the atv transversely across the incline, stop the engine, shift the drive select lever to the park position, and then block the front and rear wheels with rocks or other ob- jects. Do not park the atv at all on hills that are so steep you could not walk up them easily. 1. Bring ...

  • Page 49

    6-7 6 could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view. ● use extra caution when riding an atv with ac- cessories. The atv may handle differently than it does without accessories. Ebu26390 loading as originally equipped, th...

  • Page 50

    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 51

    7-1 7 ebu21141 riding your atv u3c261e0.Book page 1 thursday, june 29, 2006 4:15 pm.

  • Page 52

    7-2 7 ebu26574 getting to know your atv this atv is intended for recreational use by expe- rienced operators only. Even if you are an experi- enced operator of all other all terrain atvs or motorcycles, riding the atv requires special skills acquired through practice. Take your time to fully learn t...

  • Page 53

    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 54

    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 u3c261e0.Book page 4 thursday, june ...

  • Page 55

    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 56

    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 57

    7-7 7 loading and accessories as originally equipped, this atv is not designed to carry cargo or tow a trailer. If you choose to add ac- cessories so that you can carry cargo or tow a trail- er, you must use common sense and good judgment. Use extra caution when riding the atv with addi- tional load...

  • Page 58

    7-8 7 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 footboard, your foot or leg may come into con- tact with the rear wheels, which could injure you or cause an accident. Avoid wheelies and jumping. You ma...

  • Page 59

    7-9 7 ● do not park the atv during or after operation in a place where others might be likely to touch it. ● do not operate, idle, or park the atv in dry grass, dry ground cover, or combustible ma- terials. Be careful where you ride this atv is designed for use on unpaved surfaces only. Riding on pa...

  • Page 60

    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 61

    7-11 7 warning ewb01540 do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the atv on such terrain. Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction o...

  • Page 62

    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, and turning tech- niques in this area before trying more difficult ter- rain. Always avoid riding on pave...

  • Page 63

    7-13 7 warning ewb01570 always follow proper procedures for turning as described in this owner’s manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions. As you approach a curve, slow down and begin to turn t...

  • Page 64

    7-14 7 improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the atv to tip. If the atv begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be n...

  • Page 65

    7-15 7 ● never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the atv around while...

  • Page 66

    7-16 7 if your atv has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the atv on the up- hill side. Physically turn the atv aro...

  • Page 67

    7-17 7 riding downhill when riding your atv downhill, shift your weight as far to the rear and uphill side of the atv as pos- sible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compres- sion braking effect, change ...

  • Page 68

    7-18 7 ● avoid going down a hill at an angle that would cause the atv to lean sharply to one side. Go straight down the hill where possi- ble. Crossing a slope traversing a sloping surface on your atv requires you to properly position your weight to maintain proper balance. Be sure that you have lea...

  • Page 69

    7-19 7 ● shift your weight to the uphill side of the atv. Crossing through shallow water 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 ro...

  • Page 70

    7-20 7 test your brakes after leaving the water. Do not continue to ride your atv without verifying that you have regained proper braking ability. Caution: ecb00730 after riding your atv in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the...

  • Page 71

    7-21 7 1. V-belt cooling duct check hose (left front side of atv) 1. Drive select lever box check hose 1. Storage compartment drain plug 1. V-belt case drain plug u3c261e0.Book page 21 thursday, june 29, 2006 4:15 pm.

  • Page 72

    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 73

    7-23 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 re- duced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery sur...

  • Page 74

    7-24 7 ● if your atv can’t make it up a hill you are trying to climb: turn the atv around if you still have forward speed. If not, stop, dismount on the uphill side of the atv and physically turn the atv around. If the atv starts to slip backwards, do not use the rear brake if the atv is in 2wd – th...

  • Page 75

    8-1 8 ebu21654 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 76

    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 77

    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 78

    8-4 8 6 * rear brake • check operation and correct if necessary. • check brake lever 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 79

    8-5 8 15 * shock absorber as- semblies • check operation and correct if necessary. • check for oil leakage and replace if necessary. √ √ √ 16 * steering shaft • lubricate with lithium-soap-based grease. √ √ √ 17 * steering system • check operation and repair or replace if damaged. • check toe-in and...

  • Page 80

    8-6 8 26 final gear oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ 27 cooling system • check coolant level and atv for coolant leakage, and correct if necessary. √ √ √ √ √ • replace coolant. Every 2 years 28 * moving parts and cables • lubricate. √ √ √ √ 29 * drive select...

  • Page 81

    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 82

    8-8 8 ebu26401 removing and installing cowlings and panels the cowlings and panels shown need to be re- moved to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed. Ebu26582 cowling a to remove the cowl...

  • Page 83

    8-9 8 4. Remove cowling a by removing the bolts, nuts and washers. 1. Speedometer unit coupler 1. Bolt 1. Bolt (left side) 1. Bolt (right side) u3c261e0.Book page 9 thursday, june 29, 2006 4:15 pm.

  • Page 84

    8-10 8 to install the cowling 1. Connect the speedometer unit couplers. 2. Install cowling a by installing the bolts, nuts and washers. 3. Install panel b. 4. Install cowling b. Cowling b to remove the cowling 1. Remove the seat. (see page 4-12.) 2. Pull the fuel tank breather hose out of the han- d...

  • Page 85

    8-11 8 5. Remove the cowling by removing the bolts. 6. Install the fuel tank cap by turning it clockwise. To install the cowling 1. Remove the fuel tank cap by turning it coun- terclockwise. 2. Install the cowling by installing the bolts. 3. Install the fuel tank cap by turning it clockwise. 4. Plac...

  • Page 86

    8-12 8 ebu26411 panel a to remove the panel remove the bolt, and then take the panel off. To install the panel place the panel in the original position and install the bolt. Caution: ecb00380 when installing the panel, be sure not to pinch the cables or wires. Panel b to remove the panel pull outwar...

  • Page 87

    8-13 8 panel c 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 install the bolts. Panel d to remove the panel pull outward on the areas shown. 1. Tab 2. Slot 1. Panel c 2. Bolt u3c261e0.Book page 13 thursday, june 2...

  • Page 88

    8-14 8 to install the panel place the panel in its original position. 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- da...

  • Page 89

    8-15 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). Note: if th...

  • Page 90

    8-16 8 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Note: if a torque wrench is not available when installing a spark p...

  • Page 91

    8-17 8 6. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level. Note: the engine oil should be between the minimum and maximum level marks. 7. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mende...

  • Page 92

    8-18 8 to change the engine oil (with or without oil fil- ter cartridge replacement) 1. Place the atv on a level surface. 2. Remove panel d. (see page 8-8.) 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Place an oil pan under the engine to collect the used oil. 5. R...

  • Page 93

    8-19 8 note: 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. Note: 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 ...

  • Page 94

    8-20 8 10. Install panel c. 11. Install the engine oil drain bolt, and then tight- en it to the specified torque. 12. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap. Caution: ecb00300 ● in order to prevent clutch slippage (since the e...

  • Page 95

    8-21 8 13. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 14. Turn the engine off, and then check the oil lev- el and correct it if necessary. 15. Install panel d. Ebu23381 fina...

  • Page 96

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

  • Page 97

    8-23 8 caution: ecb00420 be sure no foreign material enters the final gear case. 7. Install the oil filler bolt, and then tighten it to the specified torque. 8. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 9. Install the final gear case guard by installing the b...

  • Page 98

    8-24 8 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case. 4. Install the drain bolt, and then tighten it to the specified torque. 5. Add the specified amount of the recommend- ed differential gear oil. Note: ● do...

  • Page 99

    8-25 8 ● the differential gear case capacity is greater than the recommended oil quantity, therefore the oil level cannot be accurately checked from the oil filler hole. Caution: ecb00410 be sure no foreign material enters the differen- tial gear case. 6. Install the oil filler bolt, and then tighte...

  • Page 100

    8-26 8 3. If the coolant is at or below the minimum level mark, remove the reservoir cap, add coolant or distilled water to the maximum level mark, and then install the reservoir cap. Caution: ecb00401 ● if coolant is not available, use distilled water or soft tap water instead. Do not use hard wa- ...

  • Page 101

    8-27 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. Note: ● the radiator fan is automatically switched on or off according to the coolant temperature in ...

  • Page 102

    8-28 8 4. Remove cowling a. (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. 8. After draining the coolant, thoroughly flush the cooling system with clean ta...

  • Page 103

    8-29 8 10. Connect the coolant reservoir hose. 11. Pour the recommended coolant into the reser- voir to the maximum level mark, and then in- stall the reservoir cap. 12. Pour the recommended coolant into the radia- tor until it is full. Caution: ecb00401 ● if coolant is not available, use distilled ...

  • Page 104

    8-30 8 ebu23640 cleaning the air filter element the air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. Note: there is a check hose at the ...

  • Page 105

    8-31 8 4. Pull off the lock plate, and then remove the sponge material from the air filter element frame. 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-flash-point solvents or gasoline to...

  • Page 106

    8-32 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 a quality foam air filter oil to the sponge material. Note: the sponge material should be wet but not drip- ping. 9. Pull the sponge material over the air f...

  • Page 107

    8-33 8 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the tailpipe cover by installing the bolts. War...

  • Page 108

    8-34 8 ebu23920 v-belt cooling duct check hose if dust or water collects in the v-belt cooling duct check hose, remove the hose and clean it. Ebu23930 v-belt case drain plug after riding in water deep enough to allow it to en- ter the v-belt case, remove this plug to drain the water from the case. N...

  • Page 109

    8-35 8 caution: ecb00480 the carburetor has been set and extensively tested at the yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performance of or damage to the engine. Ebu24000 adjusting the engine idling speed the engine idling speed must be ch...

  • Page 110

    8-36 8 ebu24043 adjusting the throttle cable free play the throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in the periodic maintenance and lubrication chart. The throttle cable free play should measure 3.0– 5.0 mm (0.12–0.20 in) at the throttle lev...

  • Page 111

    8-37 8 ebu24070 adjusting the drive select lever safety system cable the drive select lever safety system cable stretch- es with use, which can result in improper function. Therefore, the safety system cable should be checked and adjusted at the intervals specified in the periodic maintenance and lu...

  • Page 112

    8-38 8 note: the wheels need to be removed to check the brake pads. (see page 8-52.) ebu26471 checking the brake fluid level insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum l...

  • Page 113

    8-39 8 rear brake note: to check the rear brake fluid level, remove cowling b. (see page 8-8.) 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 dete...

  • Page 114

    8-40 8 ebu24390 checking the front brake lever free play the brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake lever should have a free play of zero mm (zero in) as shown. If the free play is incorrect, have a yamaha dealer ...

  • Page 115

    8-41 8 adjusting the brake lever free play the brake lever free play should measure 0.5–2.0 mm (0.02–0.08 in) as shown. If the free play is in- correct, adjust it as follows. 1. Loosen the locknut. 2. Turn the brake lever free play adjusting bolt in direction (a) to increase the free play, and in di...

  • Page 116

    8-42 8 checking the brake pedal position the top of the brake pedal should be positioned 67.0–77.0 mm (2.64–3.03 in) above the top of the footboard bracket. If the brake pedal position is in- correct, have a yamaha dealer adjust it. Warning ewb02070 operating with improperly serviced or adjust- ed b...

  • Page 117

    8-43 8 ebu24751 brake light switches the operation of the brake light switches must be checked and, if necessary, adjusted at the inter- vals specified in the periodic maintenance and lu- brication chart. The brake light switch for the brake pedal can be adjusted as follows, but the other brake ligh...

  • Page 118

    8-44 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 119

    8-45 8 ebu24961 checking the wheel bearings the front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a yamaha dealer check the wheel bearings. Ebu24980 lu...

  • Page 120

    8-46 8 warning ewb02160 battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. Antidote: external: flush with water. Internal: drink large quantities...

  • Page 121

    8-47 8 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 constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not...

  • Page 122

    8-48 8 the main fuse and the fuse box are located under the seat. (see page 4-12.) 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 off the main switch when checking or replacing a...

  • Page 123

    8-49 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 124

    8-50 8 3. Remove the defective bulb from the headlight unit by pulling it out. Warning ewb02220 a headlight bulb is hot when it is on and imme- diately after it is turned off. Wait for the bulb to cool before touching or removing it. You can be burned or a fire could start if the bulb touch- es some...

  • Page 125

    8-51 8 caution: ecb00670 make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 7. Adjust the headlight beam if necessary. Ebu25560 adjusting a headlight beam caution: ecb00690 it is advisable to have a yamaha dealer make this adjustment. To raise a he...

  • Page 126

    8-52 8 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. Caution: ecb00700 do not overtighten the screws, otherwise the lens may bre...

  • Page 127

    8-53 8 4. Remove the wheel. 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 whee...

  • Page 128

    8-54 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 129

    8-55 8 ebu25781 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 130

    8-56 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 131

    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 132

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

  • Page 133

    9-3 9 c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (this will limit sparking during the next step.) d. Turn the engine over several times with the starter. (this will coat the cylinder wall with oil.) e. Re...

  • Page 134

    10-1 10 ebu25960 specifications dimensions: overall length: 1978 mm (77.9 in) overall width: 1063 mm (41.9 in) overall height: 1095 mm (43.1 in) seat height: 840 mm (33.1 in) wheelbase: 1233 mm (48.5 in) ground clearance: 220 mm (8.7 in) minimum turning radius: 3000 mm (118 in) weight: with oil and ...

  • Page 135

    10-2 10 engine oil quantity: without oil filter cartridge replacement: 2.30 l (2.43 us qt) (2.02 imp.Qt) with oil filter cartridge replacement: 2.40 l (2.54 us qt) (2.11 imp.Qt) final gear oil: type: sae80 api gl-4 hypoid gear oil quantity: 0.23 l (0.24 us qt) (0.20 imp.Qt) differential gear oil: ty...

  • Page 136

    10-3 10 caster angle: 4.0 ° trail: 19.3 mm (0.76 in) front tire: type: tubeless size: at23 x 8r12 manufacturer/model: maxxis/m937 rear tire: type: tubeless size: at23 x 10r12 manufacturer/model: maxxis/m938 loading: maximum loading limit: 100.0 kg (220 lb) (total weight of rider, cargo, accessories,...

  • Page 137

    10-4 10 front suspension: type: double wishbone spring/shock absorber type: coil spring/oil damper wheel travel: 160 mm (6.3 in) rear suspension: type: swingarm spring/shock absorber type: coil spring/oil damper wheel travel: 180 mm (7.1 in) electrical system: ignition system: dc. Cdi charging syste...

  • Page 138

    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 139

    11-2 11 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 label in the space provided. This information will be need- ed when ordering spare parts from a yamaha d...

  • Page 140

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning ............................................ 8-30 axle boots .................................................................... 8-42 b battery ............................................

  • Page 141

    K key identification number ............................................. 11-1 l label locations ............................................................... 2-1 light switch .................................................................... 4-4 m main switch ......................................

  • Page 142

    Yamaha motor co., ltd. Printed in usa 2006.07-0.3 ×1 cr (e) u3c261e0.Book page 1 thursday, june 29, 2006 4:15 pm.