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Yamaha YFZ450RY Owner's Manual

Other manuals for YFZ450RY: Owner's Manual, Service Manual
Manual is about: 2009

Summary of YFZ450RY

  • Page 1

    This a manual del propietario 18p-28199-61 yfz450rsey manuel du propriÉtaire owner’s manual read this manual carefully! It contains important safety information. Lire attentivement ce manuel! Il comprend d’importantes informations de sécurité. ¡lea este manual atentamente! Contiene indicaciones impo...

  • Page 2

    Printed in japan 2009.01-0.3x1 ! (e,f,s) yamaha motor co., ltd. ✼✤✫✷✩✤❉❖❉❊ ✥.

  • Page 3: This A

    This a 18p-28199-61-e0 yfz450rsey owner’s manual read this manual carefully! It contains important safety information. ✼✤✫✷✩✤❉❖❉❊❂❂ ✤.

  • Page 4: Hicle If It Is Sold.

    Ebu29130 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. Ec declaration of conformity conforming to directive 98/37/ec (make, model) to which this declaration applies, conforms to the essential health and safety requirements of dir...

  • Page 5: Introduction

    Ebu17170 introduction ebu17321 congratulations on your purchase of the yamaha yfz450rsey. 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 ...

  • Page 6: Important Manual Information

    Ebu17330 important manual information ebu17342 failure to follow the warnings contained in this manual can result in serious in- jury or death. Particularly important information is distinguished in this manual by the following notations: * product and specifications are subject to change without no...

  • Page 7: Important Notice

    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: Table of Contents

    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 v...

  • Page 9

    Accessories and loading ........................... 6-5 riding your atv ...................................... 7-1 getting to know your atv.............. 7-2 ride with care and good jud gement.................................................. 7-2 be careful where you ride ............ 7-8 turning yo...

  • Page 10

    Adjusting a headlight beam ..................... 8-48 tail/brake light ......................................... 8-49 removing a wheel ................................... 8-49 installing a wheel ..................................... 8-49 troubleshooting ...................................... 8-50 tr...

  • Page 11: Safety Information

    1-1 1 2 3 4 5 6 7 8 9 10 11 ebu17430 safety information safety information ebu29370 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...

  • Page 12

    1-2 1 2 3 4 5 6 7 8 9 10 11 or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. ● never attempt wheelies, jumps, or other stunts. ● always inspect your atv each time you use it to make sure it is in safe operating cond...

  • Page 13: Warning

    1-3 1 2 3 4 5 6 7 8 9 10 11 backwards when climbing a hill. To avoid stall- ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointe...

  • Page 14: Change Your Clothes.

    1-4 1 2 3 4 5 6 7 8 9 10 11 cle, be sure it is kept upright. Otherwise, fuel may leak out of the fuel tank. ● gasoline is poisonous. If you should swal- low some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately. If gasoline spills on your s...

  • Page 15

    2-1 1 2 3 4 5 6 7 8 9 10 11 ebu17660 location of the warning and specification labels 5 7 4 1 2 7 6 3 ✤✫✷✬✩✤✤✲✣ ✤.

  • Page 16

    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...

  • Page 17: Warning

    2-3 1 2 3 4 5 6 7 8 9 10 11 1 gb d e f i nl p s before you operate this vehicle, read the owner’s manual. Lesen sie die bedienungsanleitung bevor sie dieses fahrzeug fahren. Antes de conducir este vehículo, lea el manual del propietario. Lire le manuel du propriétaire avant d’utiliser ce véhicule. P...

  • Page 18: Warning

    2-4 1 2 3 4 5 6 7 8 9 10 11 2 16 5fk-21697-00 2 for oceania for europe warning under 16 operating this atv if you are under the age of 16 increases your chance of severe injury or death. Never operate this atv if you are under age 16. 4d3-2816l-00 yamaha motor co., ltd. Shizuoka japan p 4gb-2155a-00...

  • Page 19: Warning

    2-5 1 2 3 4 5 6 7 8 9 10 11 gb d e f i nl p s set with tires cold. Bei kalten reifen. Ajuste con los neumáticos en frío pneus à froid. Impostare a pneumatici freddi. Wanneer de banden koud zijn. Regular com pneus frios. Ställ in med kalla däck. 27.5 kpa 0.275 kgf/cm 2 4.0 psi 30 kpa 0.30 kgf/cm 2 4....

  • Page 20: Warning

    2-6 1 2 3 4 5 6 7 8 9 10 11 for europe for oceania 6 6 4aa-22259-40 7 warning never ride as a passenger. Passengers can cause a loss of control, resulting in severe injury or death. 5fe-2151h-01 5fk-2151h-00 ✤✫✷✬✩✤✤✲✣ ✩.

  • Page 21: Description

    3-1 1 2 3 4 5 6 7 8 9 10 11 ebu17680 description ebu17690 left view ebu17700 right view 1. Front shock absorber assembly compression damping force adjusting bolt (for fast compression damping) 2. Front shock absorber assembly compression damping force adjusting screw (for slow compression damping) 3...

  • Page 22: Controls and Instruments

    3-2 1 2 3 4 5 6 7 8 9 10 11 ebu17712 controls and instruments tip the atv you have purchased may differ slightly from the figures shown in this manual. 1. Clutch lever 2. Parking brake lever 3. Left handlebar switches 4. Fuel tank cap 5. Main switch 6. Throttle lever 7. Brake lever 2 1 3 6 5 7 4 ✤✫✷...

  • Page 23: Main Switch

    4-1 1 2 3 4 5 6 7 8 9 10 11 ebu17733 instrument and control functions ebu17760 main switch the positions of the main switch are as follows: on all electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cann...

  • Page 24: Neutral Indicator Light “

    4-2 1 2 3 4 5 6 7 8 9 10 11 ebu29380 indicator light and warning lights ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu26702 coolant temperature warning light “ ” this warning light comes on when the engine over- heats. When ...

  • Page 25: ”

    4-3 1 2 3 4 5 6 7 8 9 10 11 checked by setting the engine stop switch to “ ” and turning the key to “on”. The warning light should come on for a few seconds, and then go off. If the warning light does not come on initially when the key is turned to “on”, or if the warning light re- mains on, have a ...

  • Page 26: Start Switch “

    4-4 1 2 3 4 5 6 7 8 9 10 11 ebu18100 start switch “ ” push this switch to crank the engine with the start- er. Notice ecb00050 see the starting instructions on page 6-1 prior to starting the engine. Ebu18151 light switch “ / /off” set this switch to “ ” to turn on the low beams and the taillight. Se...

  • Page 27: Speed Limiter

    4-5 1 2 3 4 5 6 7 8 9 10 11 to. This could cause an accident. Check the op- eration of the throttle lever before you start the engine. If the throttle does not work smoothly, check for the cause. Correct the problem be- fore riding the atv or consult a yamaha dealer. Ebu18321 speed limiter your atv ...

  • Page 28: (See Page 8-28.)

    4-6 1 2 3 4 5 6 7 8 9 10 11 (see page 8-28.) 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 engage the clutch, r...

  • Page 29: Brake Pedal

    4-7 1 2 3 4 5 6 7 8 9 10 11 ebu18432 brake pedal the brake pedal is located on the right side of the atv. To apply the rear brake, push down on the brake pedal. Ebu18520 parking brake lever use the parking brake before starting the engine or parking the atv, especially on a slope. To apply the parki...

  • Page 30: Warning

    4-8 1 2 3 4 5 6 7 8 9 10 11 warning ewb00220 ● always set the parking brake before starting the engine. The atv could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. ● always be sure you have released the park- ing brake before you ...

  • Page 31: Fuel

    4-9 1 2 3 4 5 6 7 8 9 10 11 ebu18812 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 1. Fuel level 2. Fuel tank filler tube recommended fuel: premium unleaded gasoline only for europe: premium unleaded gaso- l...

  • Page 32: Tip

    4-10 1 2 3 4 5 6 7 8 9 10 11 tip if knocking or pinging occurs, use a different brand of gasoline or higher octane grade. Notice ecb00070 use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the e...

  • Page 33: Tip

    4-11 1 2 3 4 5 6 7 8 9 10 11 tip make sure that the seat is securely fitted. Ebu29301 adjusting the front shock absorber assemblies these shock absorber assemblies are equipped with a spring preload adjusting nut, a rebound damping force adjusting screw, with a compres- sion damping force adjusting ...

  • Page 34: Tip

    4-12 1 2 3 4 5 6 7 8 9 10 11 crease the spring preload and thereby soften the suspension. Tip ● 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 h...

  • Page 35: Notice

    4-13 1 2 3 4 5 6 7 8 9 10 11 3. Tighten the locknut to the specified torque. Notice 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 and ...

  • Page 36: Compression Damping Force

    4-14 1 2 3 4 5 6 7 8 9 10 11 compression damping force compression damping force (for fast compression damping) to increase the compression damping force and thereby harden the compression damping, turn the adjusting bolt in direction (a). To decrease the compression damping force and thereby soften...

  • Page 37: Notice

    4-15 1 2 3 4 5 6 7 8 9 10 11 notice ecb00090 never turn an adjusting mechanism beyond the minimum and maximum settings. Tip although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual num...

  • Page 38: Accident.

    4-16 1 2 3 4 5 6 7 8 9 10 11 ● uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. Ebu29522 adjusting the rear shock absorber assembly this shock absorber assembly is equipped with a spring preload adjusting nut, a rebound damping force adjusting screw, ...

  • Page 39

    4-17 1 2 3 4 5 6 7 8 9 10 11 4. Loosen the clamp screw at the air filter case side, and then disconnect the air intake duct from the air filter case. 5. Remove the air filter case holding plate by re- moving the bolts and collars. 1. Coupler 1 1. Clamp screw 1 ✤✫✷✬✩✤✤✲✣ ✤✪.

  • Page 40

    4-18 1 2 3 4 5 6 7 8 9 10 11 6. Remove the blow-by gas chamber by remov- ing the bolt. 7. Remove the air filter case by removing the bolts. 1. Bolt 2. Collar 3. Air filter case holding plate 1 1 2 3 1. Blow-by gas chamber 2. Bolt 1 2 ✤✫✷✬✩✤✤✲✣ ✤✫.

  • Page 41: Tip

    4-19 1 2 3 4 5 6 7 8 9 10 11 8. Loosen the locknut. 9. 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. Tip ● a special wrench can be obtained at a yama...

  • Page 42: Notice

    4-20 1 2 3 4 5 6 7 8 9 10 11 (0.06 in). 10. Tighten the locknut to the specified torque. Notice ecb00080 always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque. 11. Place the air filter case in the original position, install the bolts, and then tighten th...

  • Page 43: Notice

    4-21 1 2 3 4 5 6 7 8 9 10 11 clamp screw is tightened securely. 13. Install the blow-by gas chamber by installing the bolt, and then tighten it to the specified torque. 14. Install the air filter case holding plate by install- ing the bolts and collars. 15. Connect the coupler. 16. Connect the air i...

  • Page 44: Tip

    4-22 1 2 3 4 5 6 7 8 9 10 11 tip make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting. Compression damping force panels a and d need to be removed to make this adjustment. (see page 8-8.) compression damping force (for fast compressi...

  • Page 45: Notice

    4-23 1 2 3 4 5 6 7 8 9 10 11 compression damping force (for slow compres- sion damping) to increase the compression damping force and thereby harden the compression damping, turn the adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression dampin...

  • Page 46: Warning

    4-24 1 2 3 4 5 6 7 8 9 10 11 be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. Warning ewb00440 suspension components become hot during operation. Never touch the compression damping force adjusting screw, the rebound ...

  • Page 47: Pre-Operation Checks

    5-1 1 2 3 4 5 6 7 8 9 10 11 ebu19200 pre-operation checks ebu19223 pre-operation check list before operating this atv, be sure to check the items listed in the following table. Warning ewb00480 always inspect your atv each time you use it to make sure it is in safe operating condition. Always follow...

  • Page 48

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

  • Page 49

    5-3 1 2 3 4 5 6 7 8 9 10 11 instruments, lights and switches ● check operation, and correct if necessary. 5-8 item routine page ✤✫✷✬✩✤✤✲✣ ✦.

  • Page 50: Fuel

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

  • Page 51: Brake Fluid Level

    5-5 1 2 3 4 5 6 7 8 9 10 11 have a yamaha dealer check the brake system. Brake fluid level check the brake fluid level. Add fluid if necessary. (see page 8-30.) brake fluid leakage check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly fo...

  • Page 52: Ed.

    5-6 1 2 3 4 5 6 7 8 9 10 11 by yamaha motor co., ltd. For this model. Other tire combinations are not recommend- ed. Front: manufacturer/model: dunlop/kt351 radial size: at21 x 7r10 type: tubeless rear: manufacturer/model: dunlop/kt356 radial size: at20 x 10r9 type: tubeless ● the tires should be se...

  • Page 53: Tire Wear Limit

    5-7 1 2 3 4 5 6 7 8 9 10 11 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 be incorrect. Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: ebu19830 ...

  • Page 54: Chassis Fasteners

    5-8 1 2 3 4 5 6 7 8 9 10 11 ebu19840 chassis fasteners make sure that all nuts, bolts and screws are prop- erly tightened. Ebu19850 instruments, lights and switches check that all instruments, lights and switches are working properly. Correct if necessary. 1. Tire wear limit ✤✫✷✬✩✤✤✲✣ ✫.

  • Page 55: Operation

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

  • Page 56: Tip

    6-2 1 2 3 4 5 6 7 8 9 10 11 following conditions. ● the transmission is in neutral. ● the clutch is disengaged with the transmission in gear. However, it is recommended to shift into neutral before starting the engine. 4. Completely close the throttle lever and start the engine by pushing the start ...

  • Page 57: May Result.

    6-3 1 2 3 4 5 6 7 8 9 10 11 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. Open the throttle gradually and at the same time, release the clutch lever slowly. 5. Once the atv has attained adequate speed, releas...

  • Page 58: Engine Break-In

    6-4 1 2 3 4 5 6 7 8 9 10 11 not designed to withstand the shock of forced shifting and can be damaged by shift- ing without using the clutch. Ebu20672 engine break-in tip ● for atvs equipped with an odometer or an hour meter, follow the figures given in km (mi) or the figures given in hours. ● for a...

  • Page 59: Parking On A Slope

    6-5 1 2 3 4 5 6 7 8 9 10 11 ebu20860 parking on a slope warning ewb00850 avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the atv to roll out of control, increasing the chance of an accident. If you must park on an incline, place the atv transversely across ...

  • Page 60: Loading

    6-6 1 2 3 4 5 6 7 8 9 10 11 ● choose only accessories designed for your atv. Your yamaha dealer has a variety of gen- uine yamaha accessories. Other accessories may also be available on the market. However, it is not possible for yamaha to test all non- yamaha accessories, nor control over their qua...

  • Page 61: Warning

    6-7 1 2 3 4 5 6 7 8 9 10 11 ● make sure the load does not interfere with con- trols or your ability to see where you are going. ● ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear ...

  • Page 62: Riding Your Atv

    7-1 1 2 3 4 5 6 7 8 9 10 11 ebu21141 riding your atv ✤✫✷✬✩✤✤✲✣ ✤.

  • Page 63: Getting to Know Your Atv

    7-2 1 2 3 4 5 6 7 8 9 10 11 ebu21613 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...

  • Page 64: The Child.

    7-3 1 2 3 4 5 6 7 8 9 10 11 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 operator only – passengers prohibited. Warning ewb01400 never carry a passenger. The long s...

  • Page 65: Warning

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

  • Page 66: Pre-Operation Checks

    7-5 1 2 3 4 5 6 7 8 9 10 11 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. Warning ewb01430 always inspect your atv each time you use it to make sure the atv is in safe operating con- dition. Always follo...

  • Page 67: Loading and Accessories

    7-6 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: Warning

    7-7 1 2 3 4 5 6 7 8 9 10 11 warning ewb01470 always keep both hands on the handlebars and both feet on the footboards of your atv during operation. Removing even one hand or foot can reduce your ability to control the atv or could cause you to lose your balance and fall off of the atv. If you remove...

  • Page 69: Thorized Atv Dealer.

    7-8 1 2 3 4 5 6 7 8 9 10 11 signed for use on this atv and should be installed and used according to instructions. Improper installation of accessories or modifi- cation of this atv may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an ...

  • Page 70: Warning

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

  • Page 71: Warning

    7-10 1 2 3 4 5 6 7 8 9 10 11 on unfamiliar terrain. Always be alert to chang- ing terrain conditions when operating the atv. Warning ewb01540 do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the atv on such terrain. F...

  • Page 72: Warning

    7-11 1 2 3 4 5 6 7 8 9 10 11 warning ewb01550 always mount a caution flag on the atv to make you more visible when operating in areas where you might not be seen by other vehicles. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”. Do not ride on private property witho...

  • Page 73: Warning

    7-12 1 2 3 4 5 6 7 8 9 10 11 these components. With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then release the parking brake. Open the throttle grad- ually, and at the same time, release the clutch le- ver slowly. Once the atv has attained adequa...

  • Page 74: Warning

    7-13 1 2 3 4 5 6 7 8 9 10 11 used to allow the atv to make turns quickly and easily. It is essential that this skill be learned first at low speed. Warning ewb01570 always follow proper procedures for turning as described in this owner’s manual. Practice turning at low speeds before attempting to tu...

  • Page 75: Climbing Uphill

    7-14 1 2 3 4 5 6 7 8 9 10 11 curves. 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 t...

  • Page 76: Warning

    7-15 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. Warning ewb01600 never attempt to ...

  • Page 77: Warning

    7-16 1 2 3 4 5 6 7 8 9 10 11 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 around and then descend the hill. If you start to roll backwards, do not apply the ...

  • Page 78: Warning

    7-17 1 2 3 4 5 6 7 8 9 10 11 tion. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. Whenever possible, ride your atv straight down- hill. Avoid sharp angl...

  • Page 79: Warning

    7-18 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 80: Could Lead to An Accident.

    7-19 1 2 3 4 5 6 7 8 9 10 11 in water deeper than that specified in your owner’s manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the lin- ings. If the atv is operated through deep...

  • Page 81: Riding Over Rough Terrain

    7-20 1 2 3 4 5 6 7 8 9 10 11 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 t...

  • Page 82: Warning

    7-21 1 2 3 4 5 6 7 8 9 10 11 slide. Applying the brakes or accelerating is not recommended until you have corrected the slide. 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 sta...

  • Page 83

    7-22 1 2 3 4 5 6 7 8 9 10 11 slide. (see page 7-20.) ● 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 no...

  • Page 84: Warning

    8-1 1 2 3 4 5 6 7 8 9 10 11 ebu28782 periodic maintenance and minor repair ebu21670 safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your atv in the safest and best operating condition possible. The most important points of inspection, adjustment, and...

  • Page 85: Tip

    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 86: Tip

    8-3 1 2 3 4 5 6 7 8 9 10 11 ebu21743 periodic maintenance chart for the emission control system tip ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-...

  • Page 87

    8-4 1 2 3 4 5 6 7 8 9 10 11 ebu21864 general maintenance and lubrication chart no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 air filter element ● clean and replace if...

  • Page 88

    8-5 1 2 3 4 5 6 7 8 9 10 11 10 * swingarm pivots ● check operation and for excessive play, and replace bearings if necessary. ● lubricate with lithium-soap-based grease. √ √ √ 11 * upper and lower arm pivots ● lubricate with lithium-soap-based grease. √ √ √ 12 drive chain ● check chain slack and adj...

  • Page 89

    8-6 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 ● replace. √ √ √ 22 cooling system ● check coolant level and atv for coolant leakage, and correct if necessary. √ √ √ √ √ ● replace coolant. Every 2 yea...

  • Page 90: Tip

    8-7 1 2 3 4 5 6 7 8 9 10 11 ebu29430 tip ● some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● replace the fuel hose every five years and if cracked or damaged. ● hydraulic brake service ● regularly check and, if n...

  • Page 91: Panel A

    8-8 1 2 3 4 5 6 7 8 9 10 11 ebu23090 removing and installing panels the panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. Ebu29590 panel a to remove the panel 1. Remove the sea...

  • Page 92

    8-9 1 2 3 4 5 6 7 8 9 10 11 4. Remove the quick fasteners, and then slide the panel backward and pull upward. To install the panel 1. Place the panel in the original position, and then install the quick fasteners. 1. Quick fastener 1 1 1. Quick fastener 1 ✤✫✷✬✩✤✤✲✣ ✬.

  • Page 93: Notice

    8-10 1 2 3 4 5 6 7 8 9 10 11 notice ecb00380 when installing the panel, be sure not to pinch the cables or wires. 2. Tighten the quick fasteners. 3. Install the fuel tank cap. Panels b and d to remove one of the panels 1. Remove panel a. 2. Pull the panel off. To install one of the panels 1. Place t...

  • Page 94: Panel C

    8-11 1 2 3 4 5 6 7 8 9 10 11 panel c to remove the panel 1. Remove panels a, b and d. 2. Loosen the quick fasteners, and then take the panel off. To install the panel place the panel in its original position, and then tighten the quick fasteners. Panel e to remove the panel 1. Remove panel a. 2. Loo...

  • Page 95: Panel F

    8-12 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 tighten the quick fasteners. 2. Install panel a. Panel f to remove the panel 1. Remove panel e. 2. Remove the bolts, and then take the panel off. To install the panel 1. Place the panel in the ori...

  • Page 96: Checking The Spark Plug

    8-13 1 2 3 4 5 6 7 8 9 10 11 ebu29440 checking the spark plug the spark plug is an important engine component, which should be checked periodically, preferably by a yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor...

  • Page 97: Tip

    8-14 1 2 3 4 5 6 7 8 9 10 11 tip if a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. Ebu29492 engine oil and oil filter elem...

  • Page 98: Tip

    8-15 1 2 3 4 5 6 7 8 9 10 11 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. Tip when adding oil, be careful not to overfill the en- gine oil ta...

  • Page 99: Tip

    8-16 1 2 3 4 5 6 7 8 9 10 11 6. Remove the engine oil tank filler cap and the engine oil tank drain bolt. 7. Check the washers for damage, and replace if necessary. Tip 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, an...

  • Page 100: Tip

    8-17 1 2 3 4 5 6 7 8 9 10 11 9. Check the o-rings for damage, and replace them if necessary. 10. Install a new oil filter element and the o-rings. Tip 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-...

  • Page 101: Tip

    8-18 1 2 3 4 5 6 7 8 9 10 11 12. Install the crankcase engine oil drain bolt and the engine oil tank drain bolt, and then tighten them to their specified torques. 13. Pour the specified amount of the recommend- ed engine oil through the engine oil tank filler hole, and then install and tighten the e...

  • Page 102: Notice

    8-19 1 2 3 4 5 6 7 8 9 10 11 minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 15. Turn the engine off, and then check the oil lev- el and correct it if necessary. 16. Install the engine guard by installing the bolts, and then tigh...

  • Page 103: Notice

    8-20 1 2 3 4 5 6 7 8 9 10 11 notice ecb00401 ● if coolant is not available, use distilled water or soft tap water instead. Do not use hard wa- ter or salt water since it is harmful to the en- gine. ● if water has been used instead of coolant, re- place it with coolant as soon as possible, otherwise ...

  • Page 104

    8-21 1 2 3 4 5 6 7 8 9 10 11 remove the coolant drain bolt. (use a trough or a similar object as shown.) 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 dra...

  • Page 105: Notice

    8-22 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 106: Be Reduced.

    8-23 1 2 3 4 5 6 7 8 9 10 11 otherwise the cooling system will not be pro- tected 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 effectiveness of the coolant will be reduce...

  • Page 107

    8-24 1 2 3 4 5 6 7 8 9 10 11 4. Loosen the wing bolt. 5. Remove the air filter element together with the wing bolt and washer. 6. Remove the wing bolt and washer from the air filter element. 7. Remove the sponge material from the air filter element frame. 1. Air filter case cover 2. Air filter case ...

  • Page 108: Warning

    8-25 1 2 3 4 5 6 7 8 9 10 11 8. Wash the sponge material gently but thor- oughly in solvent. Warning ewb01940 always use parts cleaning solvent to clean the sponge material. Never use low-flash-point solvents or gasoline to clean the sponge mate- rial because the engine could catch fire or ex- plode...

  • Page 109: Notice

    8-26 1 2 3 4 5 6 7 8 9 10 11 13. Install the washer onto the air filter element frame, and then insert the wing bolt into the hole in the air filter element frame. Notice ecb00451 be sure to install the washer with the bent edge facing outward as shown. 14. Insert the air filter element into the air...

  • Page 110: Cleaning The Spark Arrester

    8-27 1 2 3 4 5 6 7 8 9 10 11 ebu27701 cleaning the spark arrester select a well-ventilated area free of combustible materials and make sure the exhaust and muffler are cool. 1. Remove the bolt. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire ...

  • Page 111: Warning

    8-28 1 2 3 4 5 6 7 8 9 10 11 7. Start the engine and rev it up approximately twenty times while momentarily creating ex- haust system back pressure by blocking the end of the muffler with a shop towel. 8. Stop the engine and allow the exhaust pipe to cool. 9. Install the purging bolt and tighten it ...

  • Page 112: Valve Clearance

    8-29 1 2 3 4 5 6 7 8 9 10 11 justed if necessary, before adjusting the throttle ca- ble free play. 1. Slide the rubber cover back. 2. Loosen the locknut. 3. To increase the throttle cable free play, turn the throttle cable free play adjusting bolt in di- rection (a). To decrease the throttle cable f...

  • Page 113: Tip

    8-30 1 2 3 4 5 6 7 8 9 10 11 tip the wheels need to be removed to check the brake pads. (see page 8-49.) ebu26460 rear brake pads each rear brake pad is provided with wear indica- tor grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad...

  • Page 114: Front Brake

    8-31 1 2 3 4 5 6 7 8 9 10 11 brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Front brake rear brake tip to check the rear brake fluid level, remove the seat. (see page 4-10.) observe these precautions...

  • Page 115: Changing The Brake Fluid

    8-32 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 116: That There Is No Free Play.

    8-33 1 2 3 4 5 6 7 8 9 10 11 ● make sure the brakes operate smoothly and that there is no free play. ● make sure the brakes do not drag. ● make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedure...

  • Page 117: Tip

    8-34 1 2 3 4 5 6 7 8 9 10 11 should be performed by a yamaha dealer. Ebu24710 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...

  • Page 118: Notice

    8-35 1 2 3 4 5 6 7 8 9 10 11 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 specified torque. Notice ecb00520 when tightening the locknut, hold the adjust- ing bolt with a wrench so that it does not turn togeth...

  • Page 119: (A)

    8-36 1 2 3 4 5 6 7 8 9 10 11 ebu29541 adjusting the clutch lever free play the clutch lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The clutch lever free play should measure 8.0– 13.0 mm (0.31–0.51 in) as sho...

  • Page 120: Tip

    8-37 1 2 3 4 5 6 7 8 9 10 11 5. Tighten the locknut at the crankcase. Tip if the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a yamaha dealer check the internal clutch mechanism. Ebu26863 drive chain slack the drive chain slack shoul...

  • Page 121: Tip

    8-38 1 2 3 4 5 6 7 8 9 10 11 3. If the drive chain slack is incorrect, adjust it as follows. To adjust the drive chain slack 1. Place the atv on a level surface. 2. Loosen the rear wheel axle pinch bolts. 3. Insert a rod of a diameter of 8 mm (0.3 in) and a length of 10 cm (4 in) into one of the hol...

  • Page 122: Lubricating The Drive Chain

    8-39 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 123: Notice

    8-40 1 2 3 4 5 6 7 8 9 10 11 notice ecb00570 to prevent damaging the o-rings, do not clean the drive chain with steam cleaners, high-pres- sure washers or inappropriate solvents. 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special o-ring chain lubricant. Notice ecb005...

  • Page 124: Brake Lever

    8-41 1 2 3 4 5 6 7 8 9 10 11 brake lever clutch lever ebum0170 checking the shift pedal the operation of the shift pedal should be checked before each ride. If operation is not smooth, have a yamaha dealer check the vehicle. Ebu28871 checking and lubricating the brake pedal the operation of the brak...

  • Page 125: Pivots

    8-42 1 2 3 4 5 6 7 8 9 10 11 ebu24962 checking the wheel hub bearings the front and rear wheel hub 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 t...

  • Page 126: Left Side

    8-43 1 2 3 4 5 6 7 8 9 10 11 left side right side ebu29183 battery this model is equipped with a vrla (valve regu- lated lead acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened. Not...

  • Page 127: Warning

    8-44 1 2 3 4 5 6 7 8 9 10 11 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: ...

  • Page 128: Notice

    8-45 1 2 3 4 5 6 7 8 9 10 11 notice ecb00930 to charge a vrla (valve regulated lead acid) battery, a special (constant-voltage) battery charger is required. Using a conventional bat- tery charger will damage the battery. If you do not have access to a constant-voltage battery charger, have a yamaha ...

  • Page 129: Replacing The Fuse

    8-46 1 2 3 4 5 6 7 8 9 10 11 ebu25242 replacing the fuse the fuse holder is located under the seat. (see page 4-10.) if the fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Notice ecb00640 to prevent accidental short-circuiting, turn off the main s...

  • Page 130: Warning

    8-47 1 2 3 4 5 6 7 8 9 10 11 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the burnt-out bulb. Warning ewb02230 do not touch a headlight bulb when it is on or immediately after it is turned off. You can be burned or a fire could start if the bu...

  • Page 131: Notice

    8-48 1 2 3 4 5 6 7 8 9 10 11 notice 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. Thoroughly clean off any dirt and finger- prints on the headli...

  • Page 132: Tail/brake Light

    8-49 1 2 3 4 5 6 7 8 9 10 11 ebu26920 tail/brake light this model is equipped with an led type of tail/ brake light. If the tail/brake light does not come on, have a yamaha dealer check it. Ebu25651 removing a wheel 1. Place the atv on a level surface. 2. Loosen the wheel nuts. Front rear 3. Elevate...

  • Page 133: Troubleshooting

    8-50 1 2 3 4 5 6 7 8 9 10 11 of the wheel. ● when installing a rear wheel, make sure its wording “side facing outwards” faces outwards. 3. Lower the atv to the ground. 4. Tighten the wheel nuts to the specified torques. Ebu25740 troubleshooting although yamaha atvs receive a thorough in- spection be...

  • Page 134: Warning

    8-51 1 2 3 4 5 6 7 8 9 10 11 warning ewb02280 do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. ✤✫✷✬✩✤✤✲✣ ✤.

  • Page 135: Troubleshooting Charts

    8-52 1 2 3 4 5 6 7 8 9 10 11 ebu27691 troubleshooting charts starting problems or poor engine performance check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compression. Operate the electric ...

  • Page 136: Engine Overheating

    8-53 1 2 3 4 5 6 7 8 9 10 11 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 be...

  • Page 137: Cleaning and Storage

    9-1 1 2 3 4 5 6 7 8 9 10 11 ebu25860 cleaning and storage ebu25900 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 138: Linings.

    9-2 1 2 3 4 5 6 7 8 9 10 11 increasing the chance of an accident. Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. Ebu27260 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a...

  • Page 139: Tip

    9-3 1 2 3 4 5 6 7 8 9 10 11 points of all levers and pedals. 5. Check and, if necessary, correct the tire air pressure, and then block up the atv so that all of its wheels are off the ground. Alternative- ly, turn the wheels a little every month in order to prevent the tires from becoming degraded i...

  • Page 140: Specifications

    10-1 1 2 3 4 5 6 7 8 9 10 11 ebu25960 specifications ebu2597d dimensions: overall length: 1795 mm (70.7 in) overall width: 1240 mm (48.8 in) overall height: 1065 mm (41.9 in) seat height: 810 mm (31.9 in) wheelbase: 1270 mm (50.0 in) ground clearance: 235 mm (9.3 in) minimum turning radius: 3600 mm ...

  • Page 141: Cooling System:

    10-2 1 2 3 4 5 6 7 8 9 10 11 recommended engine oil grade: api service sg type or higher, jaso standard ma engine oil quantity: without oil filter element replacement: 1.40 l (1.48 us qt, 1.23 imp.Qt) with oil filter element replacement: 1.45 l (1.53 us qt, 1.28 imp.Qt) cooling system: coolant reser...

  • Page 142: Chassis:

    10-3 1 2 3 4 5 6 7 8 9 10 11 operation: left foot operation 1st: 35/14 (2.500) 2nd: 30/15 (2.000) 3rd: 31/19 (1.632) 4th: 28/21 (1.333) 5th: 23/21 (1.095) chassis: frame type: aluminum die-cast and steel tube frame caster angle: 5.0 ° trail: 21.0 mm (0.83 in) front tire: type: tubeless size: at21 x ...

  • Page 143: Rear Brake:

    10-4 1 2 3 4 5 6 7 8 9 10 11 operation: right hand operation 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: 250 mm (9.9 ...

  • Page 144: Consumer Information

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

  • Page 145: Tip

    11-2 1 2 3 4 5 6 7 8 9 10 11 the year of manufacture is listed in the vehicle identification number as shown in the illustration. Tip the vehicle identification number is used to identi- fy your atv. Ebu26050 model label the model label is affixed at the location in the il- lustration. Record the in...

  • Page 146

    11-3 1 2 3 4 5 6 7 8 9 10 11 1. Model label 1 ✤✫✷✬✩✤✤✲✣ ✦.

  • Page 147: Index

    Index a accessories and loading ................................................ 6-5 air filter element, cleaning............................................ 8-23 b battery.......................................................................... 8-43 brake and clutch levers, checking and lubricatin...

  • Page 148

    L label locations ............................................................... 2-1 light switch .................................................................... 4-4 m main switch .................................................................... 4-1 maintenance and lubrication chart ..........

  • Page 150

    Printed in japan 2009.01-0.3x1 ! (e) yamaha motor co., ltd. Printed on recycled paper ✼✤✫✷✩✤❉❖❉❊❂❂ ✥.