Yamaha yfz 450 2006 Owner's Manual

Summary of yfz 450 2006

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    This a owner’s manual lit-11626-20-13 5d3-28199-10 this atv should not be ridden by anyone under 16 years of age. Yfz450w warning read this manual carefully! It contains important safety information..

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    Ebu17170 introduction ebu17300 congratulations on your purchase of the yamaha yfz450w. 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 deg...

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    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...

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    Ebu17350 important notice ebu17360 welcome to the yamaha world of motor sports! This atv is designed and manufactured for off-road use only. It is illegal and unsafe to operate this atv on any public street, road or highway. This atv complies with all applicable off-road noise level and spark arrest...

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    Warning ewb00010 indicates a potential hazard that could result in serious injury or death. Ebu17420 table of contents safety information .............................. 1-1 location of the warning and specification labels ............................ 2-1 description ....................................

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    Operation .................................................. 6-1 starting a cold engine ............................... 6-1 starting a warm engine ............................. 6-3 shifting ...................................................... 6-3 engine break-in ......................................

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    Checking the wheel bearings .................. 8-46 lubricating the swingarm pivots .............. 8-46 lubricating the upper and lower arm pivots ..................................................... 8-47 battery ..................................................... 8-47 replacing the fuse ...........

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    1-1 1 2 3 4 5 6 7 8 9 10 11 ebu17430 safety information safety information ebu17571 an atv is not a toy and can be hazard- ous to operate. An atv handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as ...

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    1-2 1 2 3 4 5 6 7 8 9 10 11 conditions, and your experience. ● never attempt wheelies, jumps, or other stunts. ● 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 manu...

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    1-3 1 2 3 4 5 6 7 8 9 10 11 speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill. Turn the atv around and remount, following the procedure described in this...

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    1-4 1 2 3 4 5 6 7 8 9 10 11 ewb00021 ewb00030 warning potential hazard improper handling of gasoline. What can happen gasoline can catch fire and you could be burned. How to avoid the hazard always turn off the engine when refueling. Do not refuel right after the engine has been running and is still...

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    1-5 1 2 3 4 5 6 7 8 9 10 11 what can happen exhaust fumes are poisonous and may cause loss of consciousness and death with- in a short time. How to avoid the hazard always operate your atv in an area with ad- equate ventilation..

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    2-1 1 2 3 4 5 6 7 8 9 10 11 ebu17660 location of the warning and specification labels 1 2 3 6 6 4 5.

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    2-2 1 2 3 4 5 6 7 8 9 10 11 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 d...

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    2-3 1 2 3 4 5 6 7 8 9 10 11.

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    2-4 1 2 3 4 5 6 7 8 9 10 11.

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    3-1 1 2 3 4 5 6 7 8 9 10 11 ebu17680 description ebu17690 left view ebu17700 right view 1. Headlights 2. Fuel cock 3. Starter (choke) 4. Throttle stop screw 5. Fuse 6. Tail/brake light 7. Coolant reservoir 8. Shift pedal 9. Engine oil tank 1 2 3 4 5 6 7 8 9 1. Spark arrester 2. Seat 3. Fuel tank cap...

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    3-2 1 2 3 4 5 6 7 8 9 10 11 ebu17712 controls and instruments note: the atv you have purchased may differ slightly from the figures shown in this manual. 1. Clutch lever 2. Handlebar switches 3. Parking brake 4. Main switch 5. Throttle lever 6. Brake lever 2 1 2 3 4 5 6.

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    4-1 1 2 3 4 5 6 7 8 9 10 11 ebu17720 instrument and control functions warning ewb00010 indicates a potential hazard that could result in serious injury or death. Ebu17740 main switch the positions of the main switch are as follows: on all electrical systems are supplied with power, and the engine ca...

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    4-2 1 2 3 4 5 6 7 8 9 10 11 ebu17802 indicator light and warning light ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu17930 coolant temperature warning light “ ” this warning light comes on when the engine over- heats. When t...

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    4-3 1 2 3 4 5 6 7 8 9 10 11 ebu18060 handlebar switches ebu18070 engine stop switch “eng. Stop” set this switch to “run” 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...

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    4-4 1 2 3 4 5 6 7 8 9 10 11 return to an idle any time the hand is removed from the throttle lever. 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. Ewb00200 ebu18311 speed limiter your atv...

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    4-5 1 2 3 4 5 6 7 8 9 10 11 3. Tighten the locknut. Ewb00190 ebu18382 clutch lever the clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporat- ed in the clutch lever holder. To disengage the clutch, pull the clutch lever toward the handlebar grip. To enga...

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    4-6 1 2 3 4 5 6 7 8 9 10 11 ebu18411 brake lever the brake lever is located at the right handlebar grip. To apply the front brake, pull the brake lever toward the handlebar grip. Ebu18432 brake pedal the brake pedal is located on the right side of the atv. To apply the rear brake, push down on the b...

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    4-7 1 2 3 4 5 6 7 8 9 10 11 ebu18510 parking brake lever use the parking brake before starting the engine or parking the atv, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a). To release the parking brake, move the parking brake lever in direction (b)....

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    4-8 1 2 3 4 5 6 7 8 9 10 11 ewb00170 ebu18530 shift pedal this atv is equipped with a constant-mesh 5- speed transmission. The shift pedal is located on the left side of the engine and is used in combina- tion with the clutch when shifting. 1. Parking brake lever (unlocked position) warning potentia...

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    4-9 1 2 3 4 5 6 7 8 9 10 11 ebu18720 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. Ebu18800 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. Shift pedal 1 1. Fuel tank cap 1.

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    4-10 1 2 3 4 5 6 7 8 9 10 11 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. Your yamaha engine has been designed to use premium unleaded gasoline with a...

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    4-11 1 2 3 4 5 6 7 8 9 10 11 ewb00270 ebu18820 fuel cock the fuel cock supplies fuel from the tank to the car- buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. Off with the fuel cock lever in this position, fuel will not flow. ...

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    4-12 1 2 3 4 5 6 7 8 9 10 11 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 ...

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    4-13 1 2 3 4 5 6 7 8 9 10 11 the starter (choke). 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. Ebu18890 seat to remove the seat insert your hand between the rear of the seat and the rear fender,...

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    4-14 1 2 3 4 5 6 7 8 9 10 11 ebu19000 adjusting the front shock absorber assemblies the spring preload, rebound damping and com- pression damping forces of the front shock absorb- er assemblies can be adjusted to suit the rider’s weight and the riding conditions. Ewb00360 spring preload 1. Loosen th...

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    4-15 1 2 3 4 5 6 7 8 9 10 11 note: ● a special wrench can be obtained at a yamaha dealer to make this adjustment. ● the spring preload setting is determined by measuring distance a, shown in the illustration. The shorter distance a is, the higher the spring preload; the longer distance a is, the low...

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    4-16 1 2 3 4 5 6 7 8 9 10 11 3. Tighten the locknut to the specified torque. Caution: ecb00080 always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque. Rebound damping force turn the adjusting screw in direction (a) to increase the rebound damping force an...

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    4-17 1 2 3 4 5 6 7 8 9 10 11 the compression damping force and thereby hard- en the damping, and in direction (b) to decrease the compression damping force and thereby soft- en the damping. Caution: ecb00090 never turn an adjusting mechanism beyond the minimum and maximum settings. Note: although th...

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    4-18 1 2 3 4 5 6 7 8 9 10 11 necessary. Ewb00370 ewb00350 ebu19110 adjusting the rear shock absorber assembly the spring preload, rebound damping and com- pression damping forces of the rear shock absorb- er assembly can be adjusted to suit the rider’s weight and the riding conditions. Warning poten...

  • Page 37

    4-19 1 2 3 4 5 6 7 8 9 10 11 ewb00380 spring preload 1. Remove the seat. (see page 4-13.) 2. Loosen the clamp screw at the carburetor side, and then disconnect the air intake duct. 3. Disconnect the hose, and then remove the air filter case by removing the bolts. Warning potential hazard this shock ...

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    4-20 1 2 3 4 5 6 7 8 9 10 11 4. Loosen the locknut. 5. Turn the adjusting nut in direction (a) to in- crease the spring preload and thereby harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension. 1. Hose 1 1. Bolt 2. Air filter case 2 1.

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    4-21 1 2 3 4 5 6 7 8 9 10 11 note: ● a special wrench can be obtained at a yamaha dealer to make this adjustment. ● the spring preload setting is determined by measuring distance a, shown in the illustration. The shorter distance a is, the higher the spring preload; the longer distance a is, the low...

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    4-22 1 2 3 4 5 6 7 8 9 10 11 6. Tighten the locknut to the specified torque. Caution: ecb00080 always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque. 7. Place the air filter case in the original position, connect the air intake duct, and then tighten the...

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    4-23 1 2 3 4 5 6 7 8 9 10 11 to the standard setting. Compression damping force 1. Remove the seat. (see page 4-13.) 2. Turn the adjusting screw in direction (a) to in- crease the compression damping force and thereby harden the damping, and in direction (b) to decrease the compression damping force...

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    4-24 1 2 3 4 5 6 7 8 9 10 11 3. Install the seat. Ewb00370 warning ewb00010 indicates a potential hazard that could result in serious injury or death. Warning potential hazard suspension components become hot during operation. What can happen you could be burned. How to avoid the hazard never touch ...

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    5-1 1 2 3 4 5 6 7 8 9 10 11 ebu19200 pre-operation checks ebu19210 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...

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    5-2 1 2 3 4 5 6 7 8 9 10 11 rear brake ● check operation. If soft or spongy, have yamaha dealer bleed hydraulic system. ● check lever free play, and adjust if necessary. ● check brake pads for wear, and replace if necessary. ● check brake fluid level in reservoir, and add recommended brake fluid to ...

  • Page 45

    5-3 1 2 3 4 5 6 7 8 9 10 11 ewb00470 warning potential hazard failure to inspect the atv before operating. Failure to properly maintain the atv. What can happen increases the possibility of an accident or equipment damage. How to avoid the hazard always inspect your atv each time you use it to make ...

  • Page 46

    5-4 1 2 3 4 5 6 7 8 9 10 11 ebu19530 fuel make sure that there is sufficient fuel in the tank. (see page 4-9.) ewb00500 ebu19560 engine oil make sure that the engine oil is at the specified lev- el. Add oil as necessary. (see page 8-15.) ebu19620 coolant make sure that the coolant is at the specifie...

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    5-5 1 2 3 4 5 6 7 8 9 10 11 ebu19680 front and rear brakes brake levers and brake pedal ● check for correct free play in the brake levers and brake pedal. If the free play is incorrect, have a yamaha dealer check the brake system. (see pages 8-36 and 8-37.) ● check the operation of the brake levers ...

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    5-6 1 2 3 4 5 6 7 8 9 10 11 ebu19770 drive chain check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the drive chain as necessary. (see page 8-42.).

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    5-7 1 2 3 4 5 6 7 8 9 10 11 ebu19781 tires ewb00561 warning potential hazard operating this atv with improper tires, or with improper or uneven tire pressure. What can happen use of improper tires on this atv, or opera- tion of this atv with improper or uneven tire pressure, may cause loss of contro...

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    5-8 1 2 3 4 5 6 7 8 9 10 11 ebu19820 measuring the tire pressure use the low-pressure tire gauge. Note: the low-pressure tire gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to b...

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    5-9 1 2 3 4 5 6 7 8 9 10 11 the tire pressures to the following specifications: 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 ...

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    6-1 1 2 3 4 5 6 7 8 9 10 11 ebu19870 operation warning ewb00010 indicates a potential hazard that could result in serious injury or death. Ebu19890 ewb00610 ebu20091 starting a cold engine ewb00620 caution: ecb00150 see the “engine break-in” section on page 6-5 prior to operating the engine for the ...

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    6-2 1 2 3 4 5 6 7 8 9 10 11 light does not come on, have a yamaha deal- er check the electrical circuit. Note: this model is equipped with an ignition circuit cut- off system. The engine can be started under the following conditions. ● the transmission is in neutral. ● the clutch is disengaged with ...

  • Page 54

    6-3 1 2 3 4 5 6 7 8 9 10 11 attempt. 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine. If the engine is started with the starter (choke) in position (2), keep the starter (choke) in this position to war...

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    6-4 1 2 3 4 5 6 7 8 9 10 11 ebu20560 to start out and accelerate 1. Release the throttle lever. Caution: ecb00200 always close the throttle before shifting gears, otherwise damage to the engine and drive train may result. 2. Pull the clutch lever to disengage the clutch. 3. Shift into first gear. 4....

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    6-5 1 2 3 4 5 6 7 8 9 10 11 ewb00650 caution: ecb00180 ● even with the transmission in the neutral po- sition, do not coast for long periods of time with the engine off, and do not tow the atv for long distances. The transmission is prop- erly lubricated only when the engine is run- ning. Inadequate...

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    6-6 1 2 3 4 5 6 7 8 9 10 11 20 hours and beyond the atv can now be operated normally. Caution: ecb00220 if any engine trouble should occur during the engine break-in period, immediately have a yamaha dealer check the atv. Ebu20721 parking when parking the atv, stop the engine, shift into first gear,...

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    6-7 1 2 3 4 5 6 7 8 9 10 11 ebu20910 accessories and loading ebu20920 accessories accessories can affect the handling and control of your atv. Keep the following in mind when consid- ering an accessory or operating an atv which has accessories. ● choose only accessories designed for your atv. Your y...

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    6-8 1 2 3 4 5 6 7 8 9 10 11 ● never exceed the weight limits shown. An over- loaded atv can be unstable. ● if you are carrying cargo and towing a trailer, in- clude the tongue weight in the maximum atv load limit. ● load cargo on the carriers as close to the center of the atv as possible. Put cargo ...

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    7-1 1 2 3 4 5 6 7 8 9 10 11 ebu21131 riding your atv.

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    7-2 1 2 3 4 5 6 7 8 9 10 11 warning ewb00010 indicates a potential hazard that could result in serious injury or death. Ebu21591 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...

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    7-3 1 2 3 4 5 6 7 8 9 10 11 riding your atv requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Not recommended for children under 16 years of age. Ewb00901 how to avoid the hazard beginning and...

  • Page 63

    7-4 1 2 3 4 5 6 7 8 9 10 11 this atv is designed to carry operator only – passengers prohibited. Ewb00910 apparel ewb00920 warning potential hazard carrying a passenger on this atv. What can happen greatly reduces your ability to balance and control this atv. Could cause an accident, resulting in ha...

  • Page 64

    7-5 1 2 3 4 5 6 7 8 9 10 11 do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. What can happen operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of ...

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    7-6 1 2 3 4 5 6 7 8 9 10 11 ewb00930 pre-operation checks always perform the pre-operation checks listed on page 5-1 before riding for proper care of the atv and to ensure safety. Ewb00940 warning potential hazard operating this atv after consuming alcohol or drugs. What can happen could seriously a...

  • Page 66

    7-7 1 2 3 4 5 6 7 8 9 10 11 ewb00950 warning ewb00010 indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. Ewb00960 speed limiter for riders less experienced with this model, the throttle lever housing is equi...

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    7-8 1 2 3 4 5 6 7 8 9 10 11 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 ...

  • Page 68

    7-9 1 2 3 4 5 6 7 8 9 10 11 during operation always keep your feet on the footboards during op- eration, otherwise they may contact the rear wheels. Ewb00980 avoid wheelies and jumping. You may lose control of the atv or overturn. Ewb00990 warning potential hazard removing hands from handlebars or f...

  • Page 69

    7-10 1 2 3 4 5 6 7 8 9 10 11 modifications ewb01000 exhaust system the exhaust system on the atv is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the atv in a place where pedestrians or children are not likely to touch it. Ewb01010 warning potenti...

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    7-11 1 2 3 4 5 6 7 8 9 10 11 be careful where you ride this atv is designed for off-road use only. Riding on paved surfaces can cause loss of control. Ewb01020 how to avoid the hazard do not operate, idle, or park the atv in dry grass or other dry ground cover. Keep the engine area free of dry grass...

  • Page 71

    7-12 1 2 3 4 5 6 7 8 9 10 11 do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. Ewb01030 know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden ...

  • Page 72

    7-13 1 2 3 4 5 6 7 8 9 10 11 ewb01040 warning potential hazard failure to use extra care when operating this atv on unfamiliar terrain. What can happen you can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the atv overturning or going out of control. How to a...

  • Page 73

    7-14 1 2 3 4 5 6 7 8 9 10 11 ewb01050 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. Warning potential hazard failure to use extra care when operating on excessively rough, slipp...

  • Page 74

    7-15 1 2 3 4 5 6 7 8 9 10 11 ewb01060 do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. Select a large, flat area off-road to become familiar with your atv. Make sure that this area is free of obstacles and other riders. You should practice c...

  • Page 75

    7-16 1 2 3 4 5 6 7 8 9 10 11 the shift pedal. Remember that the engine and ex- haust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, a...

  • Page 76

    7-17 1 2 3 4 5 6 7 8 9 10 11 ewb01070 turning your atv to achieve maximum traction while riding off-road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. There- fore, unless the wheel on the inside of the turn is al- lowed to slip or lose some traction, the a...

  • Page 77

    7-18 1 2 3 4 5 6 7 8 9 10 11 this procedure should be practiced at slow speed many times in a large off-road area with no obsta- cles. If an incorrect technique is used, your atv may continue to go straight. If the atv doesn’t turn, come to a stop and then practice the proce- dure again. If the ridi...

  • Page 78

    7-19 1 2 3 4 5 6 7 8 9 10 11 it is important when climbing a hill to make sure that your weight is transferred forward on the atv. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars. Ewb01100 what can happen the at...

  • Page 79

    7-20 1 2 3 4 5 6 7 8 9 10 11 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 you still have forward motion (provided you have the room to do so) and go down the hill. Ewb01190 warning potential hazard ...

  • Page 80

    7-21 1 2 3 4 5 6 7 8 9 10 11 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. Physi...

  • Page 81

    7-22 1 2 3 4 5 6 7 8 9 10 11 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. Choose a low gear which will allow the en- gine compression to do most of the braking for ...

  • Page 82

    7-23 1 2 3 4 5 6 7 8 9 10 11 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 learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slip- ...

  • Page 83

    7-24 1 2 3 4 5 6 7 8 9 10 11 steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill. If your atv does begin to tip over, gradually steer in the downhill direction if there are no obstacles in ...

  • Page 84

    7-25 1 2 3 4 5 6 7 8 9 10 11 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 care- fully. Ewb01150 test your brakes after leaving the water. Do not contin...

  • Page 85

    7-26 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00240 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. Wash the atv in fresh water if it has been operated in salt water or muddy conditions. Riding over rough terrain riding o...

  • Page 86

    7-27 1 2 3 4 5 6 7 8 9 10 11 sliding and skidding care should be used when riding on loose or slip- pery surfaces since the atv may slide. If unex- pected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positio...

  • Page 87

    7-28 1 2 3 4 5 6 7 8 9 10 11 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 ...

  • Page 88

    7-29 1 2 3 4 5 6 7 8 9 10 11 lean more into the turn to regain balance. If nec- essary, gradually let off the throttle and/or steer to the outside of the turn. (see page 7-17.) ● if your atv starts to slide sideways: steer in the direction of the slide if you have the room. Applying the brakes or ac...

  • Page 89

    8-1 1 2 3 4 5 6 7 8 9 10 11 ebu21641 periodic maintenance and minor repair ebu21660 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...

  • Page 90

    8-2 1 2 3 4 5 6 7 8 9 10 11 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 cert...

  • Page 91

    8-3 1 2 3 4 5 6 7 8 9 10 11 ebu21742 periodic maintenance chart for the emission control system 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 inte...

  • Page 92

    8-4 1 2 3 4 5 6 7 8 9 10 11 6 * exhaust system ● check for leakage and replace gasket(s) if neces- sary. ● check for looseness and tighten all screw clamps and joints if necessary. √ √ √ 7 spark arrester ● clean. √ √ √ no. Item check or maintenance job initial every whichev- er comes first month 1 3...

  • Page 93

    8-5 1 2 3 4 5 6 7 8 9 10 11 ebu21862 general maintenance and lubrication chart no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 air filter element ● clean and replace if...

  • Page 94

    8-6 1 2 3 4 5 6 7 8 9 10 11 9 * wheel bearings ● check for looseness or damage, and replace if necessary. √ √ √ √ 10 * swingarm pivots ● check operation and for excessive play, and replace bearings if necessary. ● lubricate with molybdenum disulfide grease. √ √ √ 11 * upper and lower arm pivots ● lu...

  • Page 95

    8-7 1 2 3 4 5 6 7 8 9 10 11 20 engine oil ● change. ● check atv for oil leakage, and correct if neces- sary. √ √ √ √ 21 engine oil filter ele- ment ● clean or replace if necessary. √ √ √ 22 cooling system ● check coolant level and atv for coolant leakage, and correct if necessary. √ √ √ √ √ ● replac...

  • Page 96

    8-8 1 2 3 4 5 6 7 8 9 10 11 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 mast...

  • Page 97

    8-9 1 2 3 4 5 6 7 8 9 10 11 warning ewb00010 indicates a potential hazard that could result in serious injury or death. Ebu23080 removing and installing the panel the panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time th...

  • Page 98

    8-10 1 2 3 4 5 6 7 8 9 10 11 to install the panel 1. Place the panel in the original position, and then install the quick fastener screw and the bolts. 2. Install the seat. Ebu23231 checking the spark plug the spark plug is an important engine component, which is easy to check. Since heat and deposi...

  • Page 99

    8-11 1 2 3 4 5 6 7 8 9 10 11 dance with the periodic maintenance and lubrica- tion chart. In addition, the condition of the spark plug can reveal the condition of the engine. To remove the spark plug 1. Remove the seat. (see page 4-13.) 2. Remove the bolts and the quick fastener screws shown. 3. Rem...

  • Page 100

    8-12 1 2 3 4 5 6 7 8 9 10 11 4. Pull the panel backward, and then remove the panel. 5. Install the fuel tank cap by turning it clockwise. 6. Remove the bolt, lift the rear of the fuel tank, and then tilt it back. 7. Remove the spark plug cap. How to avoid the hazard always turn off the engine before...

  • Page 101

    8-13 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00390 do not use any tools to remove or install the spark plug cap, otherwise the ignition coil cou- pler may be damaged. The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly. To remove the spark plug cap, s...

  • Page 102

    8-14 1 2 3 4 5 6 7 8 9 10 11 and excessive carbon or other deposits, and replace it if necessary. To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification. 2. Clean the surface of the spark plug gasket and its mating sur...

  • Page 103

    8-15 1 2 3 4 5 6 7 8 9 10 11 8. Install the fuel tank cap by turning it clockwise. 9. Install the bolts and the quick fastener screws. 10. Install the seat. Ebu23303 engine oil and oil filter element the engine oil level should be checked before each ride. In addition, the oil must be changed and th...

  • Page 104

    8-16 1 2 3 4 5 6 7 8 9 10 11 note: the engine oil should be between the minimum and maximum level marks. 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type through the engine oil tank filler hole to raise it to the correct level. Note: when addin...

  • Page 105

    8-17 1 2 3 4 5 6 7 8 9 10 11 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. Remove the crankcase engine oil filler cap and the crankcase engine oil drain bolt. 6. Remove the engine oil tank filler cap and ...

  • Page 106

    8-18 1 2 3 4 5 6 7 8 9 10 11 7. Check the washers for damage, and replace if necessary. Note: skip steps 8–11 if the oil filter element is not being replaced. 8. Remove the oil filter element cover by remov- ing the bolts, and then remove the oil filter el- ement. 9. Check the o-rings for damage, an...

  • Page 107

    8-19 1 2 3 4 5 6 7 8 9 10 11 10. Install a new oil filter element and the o-rings. Note: make sure that the o-rings are properly seated. 11. Install the oil filter element cover by installing the bolts, and then tighten them to the speci- fied torque. 12. Install the crankcase engine oil drain bolt ...

  • Page 108

    8-20 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00300 ● in order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “cd” or oils of a higher quality than specified. In addition, do not use oils labe...

  • Page 109

    8-21 1 2 3 4 5 6 7 8 9 10 11 ebu23490 to check the coolant level 1. Place the atv on a level surface. Note: the coolant level must be checked on a cold en- gine since the level varies with engine tempera- ture. 2. Check the coolant level in the coolant reser- voir. Note: the coolant should be betwee...

  • Page 110

    8-22 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00400 ● if coolant is not available, use distilled water or soft tap water instead. Do not use hard wa- ter or salt water since it is harmful to the en- gine. ● if water has been used instead of coolant, re- place it with coolant as soon as possible, otherwis...

  • Page 111

    8-23 1 2 3 4 5 6 7 8 9 10 11 4. Remove the radiator cap. 5. Remove the coolant reservoir by removing the bolts. 6. Remove the coolant reservoir cap, and then turn the coolant reservoir upside down to empty it. 1. Coolant drain bolt 2. Trough 2 1 1. Radiator cap 1.

  • Page 112

    8-24 1 2 3 4 5 6 7 8 9 10 11 7. After draining the coolant, thoroughly flush the cooling system with clean tap water. 8. Install the coolant reservoir by installing the bolts. 9. Replace the coolant drain bolt washer if it is damaged, install the coolant drain bolt, and then tighten it to the specif...

  • Page 113

    8-25 1 2 3 4 5 6 7 8 9 10 11 otherwise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion. ● 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...

  • Page 114

    8-26 1 2 3 4 5 6 7 8 9 10 11 3. Loosen the wing bolt. 4. Remove the air filter element together with the wing bolt. 5. Remove the wing bolt from the air filter ele- ment. 6. Remove the sponge material from the air filter element frame. 1. Air filter case cover 2. Air filter case holder 2 1 1. Wing b...

  • Page 115

    8-27 1 2 3 4 5 6 7 8 9 10 11 7. Wash the sponge material gently but thor- oughly in solvent. Ewb01900 8. Squeeze the excess solvent out of the sponge material and let it dry. Caution: ecb00440 do not twist the sponge material when squeez- ing it. 9. Check the sponge material and replace it if damage...

  • Page 116

    8-28 1 2 3 4 5 6 7 8 9 10 11 15. Install the seat. Note: the air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the atv is operated in extremely dusty ar- eas. Each time the air filter element maintenance is performed, check the air inlet of th...

  • Page 117

    8-29 1 2 3 4 5 6 7 8 9 10 11 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the bolt and tighten it. 6. Remove the purging bolt. 7. Start the engine and rev it up approximately twenty times while momentarily creating ex- haust system back pressure by blocking the end of...

  • Page 118

    8-30 1 2 3 4 5 6 7 8 9 10 11 ebu23940 adjusting the carburetor the carburetor should be checked and, if neces- sary, adjusted at the intervals specified in the peri- odic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adjustment. ...

  • Page 119

    8-31 1 2 3 4 5 6 7 8 9 10 11 chart. The throttle cable free play should measure 2.0– 4.0 mm (0.08–0.16 in) at the throttle lever. Period- ically check the throttle cable free play and, if nec- essary, adjust it as follows. Note: the engine idling speed must be checked, and ad- justed if necessary, b...

  • Page 120

    8-32 1 2 3 4 5 6 7 8 9 10 11 ebu24130 checking the front and rear brake pads the front and rear brake pads must be checked for wear at the intervals specified in the periodic main- tenance and lubrication chart. Ebu27711 front brake pads each brake pad is provided with wear indicator grooves, which ...

  • Page 121

    8-33 1 2 3 4 5 6 7 8 9 10 11 place the brake pads as a set. Ebu26831 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 level mark and replenish i...

  • Page 122

    8-34 1 2 3 4 5 6 7 8 9 10 11 rear brake note: to check the rear brake fluid level, remove the seat. (see page 4-13.) if the rear brake fluid level is low, replenish as fol- lows. 1. Remove the brake fluid reservoir bracket bolt. 2. Pull the brake fluid reservoir out to the side as shown. 1. Minimum ...

  • Page 123

    8-35 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00780 do not tilt the rear brake fluid reservoir exces- sively when removing or installing the rear brake fluid reservoir. Also do not twist or pull the hose of the reservoir. 3. Remove the brake fluid reservoir cap, and then refill with brake fluid. 4. Insta...

  • Page 124

    8-36 1 2 3 4 5 6 7 8 9 10 11 ● refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. ● be careful that water does not enter the brake fluid reservoir when refilling. Water will signifi- cantly lower the boiling point o...

  • Page 125

    8-37 1 2 3 4 5 6 7 8 9 10 11 ewb02010 ebu24601 checking the brake pedal position the brake pedal position must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The top of the brake pedal should be positioned 11.7 mm (0.46 in) below ...

  • Page 126

    8-38 1 2 3 4 5 6 7 8 9 10 11 ebu24700 adjusting the parking brake free play the parking brake free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Cable length “a” should measure 47–51 mm (1.9– 2.0 in). Adjust the parking...

  • Page 127

    8-39 1 2 3 4 5 6 7 8 9 10 11 note: if the cable length cannot be adjusted to specifica- tion, consult a yamaha dealer. 5. Tighten the locknut on the brake cable. 6. Turn in the adjusting bolt at the rear brake cal- iper until it feels tight, then turn it out 1/8 turn and tighten its locknut to the s...

  • Page 128

    8-40 1 2 3 4 5 6 7 8 9 10 11 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 light switches should be adjusted by a yamaha dealer. Note: the brake light switch is properly adjusted when the...

  • Page 129

    8-41 1 2 3 4 5 6 7 8 9 10 11 1. Loosen the locknut at the clutch lever. 2. To increase the clutch lever free play, turn the adjusting bolt at the clutch lever in direction (a), and to decrease it, turn the bolt in direction (b). 3. Tighten the locknut at the clutch lever. If the specified free play ...

  • Page 130

    8-42 1 2 3 4 5 6 7 8 9 10 11 ebu26860 drive chain slack the drive chain slack should be checked before each ride and adjusted if necessary. To check the drive chain slack 1. Place the atv on a level surface. Note: when checking and adjusting the drive chain slack, there should be no weight on the at...

  • Page 131

    8-43 1 2 3 4 5 6 7 8 9 10 11 note: a rod can be obtained at a yamaha dealer to make this adjustment. 3. Shift the transmission into neutral. 4. To tighten the drive chain, push the atv back- ward. To loosen the drive chain, push the atv forward. Caution: ecb00541 improper drive chain slack will over...

  • Page 132

    8-44 1 2 3 4 5 6 7 8 9 10 11 ebu24880 lubricating the drive chain the drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as ...

  • Page 133

    8-45 1 2 3 4 5 6 7 8 9 10 11 ewb02120 ebu24920 checking and lubricating the brake and clutch levers the operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Brake lever clutch lever warning potential hazard damaged contr...

  • Page 134

    8-46 1 2 3 4 5 6 7 8 9 10 11 ebu24930 checking and lubricating the brake and shift pedals the operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Brake pedal ebu24961 checking the wheel bearings the front and rear wheel ...

  • Page 135

    8-47 1 2 3 4 5 6 7 8 9 10 11 ebu25030 lubricating the upper and lower arm pivots the upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun. Left side right side ebu25212 battery t...

  • Page 136

    8-48 1 2 3 4 5 6 7 8 9 10 11 as this would permanently damage the battery. Ewb02140 to charge the battery have a yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the atv is equipped with optional ele...

  • Page 137

    8-49 1 2 3 4 5 6 7 8 9 10 11 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 have access to a constant-voltage battery charg- er, have a yamaha dealer charg...

  • Page 138

    8-50 1 2 3 4 5 6 7 8 9 10 11 3. Turn the key to “on” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a yamaha dealer check the electrical system. Ebu25430 replacing a headlight bulb if a headlight bulb burns out, replace it as follows...

  • Page 139

    8-51 1 2 3 4 5 6 7 8 9 10 11 ewb02180 5. Place a new headlight bulb into position. Caution: ecb00650 do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affect- ed. Thorou...

  • Page 140

    8-52 1 2 3 4 5 6 7 8 9 10 11 8. Connect the headlight coupler. 9. Install the headlight unit by installing the bolts. 10. Adjust the headlight beam if necessary. Ebu25550 adjusting a headlight beam caution: ecb00690 it is advisable to have a yamaha dealer make this adjustment. To raise a headlight b...

  • Page 141

    8-53 1 2 3 4 5 6 7 8 9 10 11 rear 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Ebu25670 installing a wheel 1. Install the wheel and the nuts. Note: when installing a front wheel, make sure its arrow mark points toward the rota...

  • Page 142

    8-54 1 2 3 4 5 6 7 8 9 10 11 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 troubleshooting charts represent quick and easy procedures fo...

  • Page 143

    8-55 1 2 3 4 5 6 7 8 9 10 11 ebu25771 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 ...

  • Page 144

    8-56 1 2 3 4 5 6 7 8 9 10 11 engine overheating ewb02270 note: if coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible. Warning potential hazard removing the radiator cap when the engine and radiator are sti...

  • Page 145

    9-1 1 2 3 4 5 6 7 8 9 10 11 ebu25860 cleaning and storage ebu25890 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 exh...

  • Page 146

    9-2 1 2 3 4 5 6 7 8 9 10 11 engine and let it idle for several minutes. Ewb02300 ebu25932 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a porous cover. Caution: ecb00720 ● storing the atv in a poorly ventilated room or covering it with ...

  • Page 147

    9-3 1 2 3 4 5 6 7 8 9 10 11 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...

  • Page 148

    10-1 1 2 3 4 5 6 7 8 9 10 11 ebu25960 specifications ebu25975 dimensions: overall length: 1840 mm (72.4 in) overall width: 1170 mm (46.1 in) overall height: 1090 mm (42.9 in) seat height: 810 mm (31.9 in) wheelbase: 1280 mm (50.4 in) ground clearance: 255 mm (10.0 in) minimum turning radius: 3500 mm...

  • Page 149

    10-2 1 2 3 4 5 6 7 8 9 10 11 engine oil quantity: without oil filter element replacement: 1.75 l (1.85 us qt) (1.54 imp.Qt) quantity in oil tank: 1.55 l (1.64 us qt) (1.36 imp.Qt) quantity in crankcase: 0.20 l (0.21 us qt) (0.18 imp.Qt) with oil filter element replacement: 1.85 l (1.96 us qt) (1.63 ...

  • Page 150

    10-3 1 2 3 4 5 6 7 8 9 10 11 5th: 21/20 (1.050) chassis: frame type: steel tube frame caster angle: 5.0 ° trail: 21.0 mm (0.83 in) front tire: type: tubeless size: at21 x 7-10 manufacturer/model: dunlop/kt341 radial rear tire: type: tubeless size: at20 x 10-9 manufacturer/model: dunlop/kt355a radial...

  • Page 151

    10-4 1 2 3 4 5 6 7 8 9 10 11 recommended fluid: dot 4 rear brake: type: single disc brake operation: right foot operation recommended fluid: dot 4 front suspension: type: double wishbone spring/shock absorber type: coil spring/gas-oil damper wheel travel: 230 mm (9.1 in) rear suspension: type: swing...

  • Page 152

    11-1 1 2 3 4 5 6 7 8 9 10 11 ebu25981 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...

  • Page 153

    11-2 1 2 3 4 5 6 7 8 9 10 11 note: the vehicle identification number is used to identi- fy 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 spar...

  • Page 154

    11-3 1 2 3 4 5 6 7 8 9 10 11 ebu26060 noise regulation tampering with noise control system prohibited: federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device ...

  • Page 155

    11-4 1 2 3 4 5 6 7 8 9 10 11 ebu26080 maintenance record copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is require...

  • Page 156

    11-5 1 2 3 4 5 6 7 8 9 10 11 ebu26501 yamaha motor corporation, u.S.A. Atv limited warranty yamaha motor corporation, u.S.A. Hereby warrants that new yamaha atvs purchased from an authorized yamaha atv dealer in the continental united states will be free from defects in material and workmanship for ...

  • Page 157

    11-6 1 2 3 4 5 6 7 8 9 10 11 warranty questions and answers q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spa...

  • Page 158

    11-7 1 2 3 4 5 6 7 8 9 10 11 ebu26122 yamaha extended service (y.E.S.) keep your yamaha protected even after your warranty expires with genuine yamaha extended ser vice (y.E.S.). Y.E.S. Is designed and administered by yamaha motor corporation to provide maximum owner satisfaction. You get uninterr u...

  • Page 159

    11-8 1 2 3 4 5 6 7 8 9 10 11 we urge you to act now. You’ll get the excellent benefits of trip coverage r ight away, and you’ll rest easy knowing you’ll have strong factor y-backed protection even after your ya m a h a l i m i t e d wa r ra n t y ex p i r e s. Yo u c a n a l s o s ave money: y.E.S. ...

  • Page 160

    11-9 1 2 3 4 5 6 7 8 9 10 11 ebu26132.

  • Page 161

    Index a accessories and loading ................................................ 6-7 air filter element, cleaning............................................ 8-25 b battery.......................................................................... 8-47 brake and clutch levers, checking and lubricatin...

  • Page 162

    K key identification number..............................................11-1 l label locations ................................................................2-1 light switch .....................................................................4-3 m main switch .......................................

  • Page 163

    Printed in japan 2006.04-5.0x1 ! (e) yamaha motor co., ltd. Printed on recycled paper locate and read owner’s manual. Follow all instructions and warnings. (for replacement manual, call 1-800-532-1558) warning always : use proper riding techniques to avoid vehicle overturns on hills and rough terrai...

  • Page 164: Read    Carefull

    Dear new yamaha atv owner: congratulations on the purchase of your new yamaha atv. You have purchased a quality yamaha product that , with proper use and care , will provide hours of riding pleasure. Before you operate your new atv, yamaha recommends these important points: 8 read your owner ’ s man...

  • Page 165

    No postage necessary if mailed in the united states first class permit no. 4 cypress, ca postage will be paid by addressee yamaha motor corporation u.S.A. P.O. Box 6555 cypress, california 90630-9989 attn: sales administration atv card for us 4/2/03 9:06 am page 2.