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  5. Owner's Manual

Yamaha YFZ450W Owner's Manual - Yfz450X/yfz450Spx

Other manuals for YFZ450W: Owner's Manual, Owner's Manual

Summary of YFZ450W

  • Page 1

    This a manual del propietario 5d3-28199-62 yfz450x/yfz450spx manuel du propriÉtaire owner’s manual.

  • Page 2

    Printed in japan 2007.04-0.8x1 ! (e,f,s) yamaha motor co., ltd..

  • Page 3: Yfz450X/yfz450Spx

    This a 5d3-28199-62-e0 yfz450x/yfz450spx owner’s manual.

  • Page 5

    Ebu17170 introduction ebu17320 congratulations on your purchase of the yamaha yfz450x/yfz450spx. This atv represents the result of many years of yamaha experience in the production of fine sporting, touring, and pacesetting racing ma- chines. With the purchase of this yamaha, you can now appreciate ...

  • Page 6

    Ebu17330 important manual information ebu17341 failure to follow the warnings contained in this manual can result in serious in- jury or death. Particularly important information is distinguished in this manual by the following notations: * product and specifications are subject to change without no...

  • Page 7

    Ebu17350 important notice ebu17370 welcome to the yamaha world of motor sports! This atv is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this atv on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations bef...

  • Page 8

    Ebu17420 table of contents safety information .............................. 1-1 location of the warning and specification labels ............................ 2-1 description .............................................. 3-1 left view ..................................................... 3-1 right ...

  • Page 9

    Parking ...................................................... 6-5 parking on a slope .................................... 6-6 accessories and loading ........................... 6-6 riding your atv ...................................... 7-1 getting to know your atv.............. 7-2 ride with care ...

  • Page 10

    Replacing a headlight bulb ...................... 8-47 adjusting a headlight beam ..................... 8-49 replacing the tail/brake light bulb ........... 8-50 removing a wheel ................................... 8-50 installing a wheel ..................................... 8-50 troubleshooting .....

  • Page 11

    1-1 1 2 3 4 5 6 7 8 9 10 11 ebu17430 safety information safety information ebu17591 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 ...

  • Page 12

    1-2 1 2 3 4 5 6 7 8 9 10 11 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 condition. Al- ways follow the inspection and maint...

  • Page 13

    1-3 1 2 3 4 5 6 7 8 9 10 11 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 pointed straight up- hill. Turn the atv around and rem...

  • Page 14

    1-4 1 2 3 4 5 6 7 8 9 10 11 cock is in the “off” position. Otherwise, fuel may leak out of the carburetor or fuel tank. ● gasoline is poisonous. If you should swal- low some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately. If gasoline spil...

  • Page 15

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

  • 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

    2-3 1 2 3 4 5 6 7 8 9 10 11 yamaha motor co., ltd. Shizuoka japan p 4gb-2155a-00 for europe 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. ...

  • Page 18

    2-4 1 2 3 4 5 6 7 8 9 10 11 3 use premium unleaded gasoline with min. 97 octane(ron). Nur super bleifrei mit mindestoktanzahl 97 (roz) tanken. Utilice gasolina sin plomo que tenga como m’nimo 97 octanos (ron). Utiliser une essence super sans plomb dÕun indice dÕoctane (ron) de min. 97. Utilizzare be...

  • Page 19

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

  • Page 20

    2-6 1 2 3 4 5 6 7 8 9 10 11 6 5tg-21696-40 27.5 kpa 0.275 kgf/cm 2 4.0 psi 30 kpa 0.30 kgf/cm 2 4.4 psi gb d e f i nl p s set with tires cold. Pneus ˆ froid. Bei kalten reifen. Ajuste con los neum‡ticos an fr’o. Impostare a pneumatici freddi. StŠll in med kalla dŠck. Wanneer de banden koud zijn. Reg...

  • Page 21

    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...

  • Page 22

    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.

  • Page 23

    4-1 1 2 3 4 5 6 7 8 9 10 11 ebu17730 instrument and control functions ebu17740 main switch the positions of the main switch are as follows: on all electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved. Off all electrical systems are off. The key can b...

  • Page 24

    4-2 1 2 3 4 5 6 7 8 9 10 11 heats. When this occurs during operation, stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes. The electrical circuit of the warning light can be checked according to the following procedure. 1. Set the engine stop switch to “ ” a...

  • Page 25

    4-3 1 2 3 4 5 6 7 8 9 10 11 ebu18090 start switch “start” push this switch to crank the engine with the start- er. Caution: ecb00050 see the starting instructions on page 6-1 prior to starting the engine. Ebu18120 light switch “lights” set this switch to “lo” to turn on the low beams and the taillig...

  • Page 26

    4-4 1 2 3 4 5 6 7 8 9 10 11 fore riding the atv or consult a yamaha dealer. Ebu18321 speed limiter your atv was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To inc...

  • Page 27

    4-5 1 2 3 4 5 6 7 8 9 10 11 (see page 8-30.) 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 28

    4-6 1 2 3 4 5 6 7 8 9 10 11 ebu18520 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)....

  • Page 29

    4-7 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 30

    4-8 1 2 3 4 5 6 7 8 9 10 11 ebu18810 fuel make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Note: if knocking or pinging occurs, use a different brand 1. Fuel tank cap 1 1. Fuel level 2. Filler tube recommended fuel: premium unleaded g...

  • Page 31

    4-9 1 2 3 4 5 6 7 8 9 10 11 of gasoline or higher octane grade. Caution: ecb00070 use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Warning ewb00310 ● do not overfill the fu...

  • Page 32

    4-10 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 ...

  • Page 33

    4-11 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, ...

  • Page 34

    4-12 1 2 3 4 5 6 7 8 9 10 11 ebu27903 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 bolt (for fast com- pression damping), and a com...

  • Page 35

    4-13 1 2 3 4 5 6 7 8 9 10 11 the suspension. 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 distan...

  • Page 36

    4-14 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...

  • Page 37

    4-15 1 2 3 4 5 6 7 8 9 10 11 compression damping force compression damping force (for fast compression damping) 1. To increase the compression damping force and thereby harden the compression damp- ing, turn the adjusting bolt in direction (a). To decrease the compression damping force and thereby s...

  • Page 38

    4-16 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00090 never turn an adjusting mechanism beyond the minimum and maximum settings. Note: 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...

  • Page 39

    4-17 1 2 3 4 5 6 7 8 9 10 11 setting. Warning ewb00400 always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. Ebu27923 adjusting the rear shock absorber assembly t...

  • Page 40

    4-18 1 2 3 4 5 6 7 8 9 10 11 3. Disconnect the hose, and then remove the air filter case by removing the bolts. 1. Clamp screw 1 1. Hose 1.

  • Page 41

    4-19 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. Note: ● a special wrench can be obtained at a ya...

  • Page 42

    4-20 1 2 3 4 5 6 7 8 9 10 11 (0.06 in). 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 ...

  • Page 43

    4-21 1 2 3 4 5 6 7 8 9 10 11 note: make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting. Compression damping force compression damping force (for fast compression damping) 1. Remove the seat. (see page 4-11.) 2. To increase the compr...

  • Page 44

    4-22 1 2 3 4 5 6 7 8 9 10 11 3. Install the seat. Note: make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting. Compression damping force (for slow compres- sion damping) 1. Remove the seat. (see page 4-11.) 2. To increase the compress...

  • Page 45

    4-23 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00090 never turn an adjusting mechanism beyond the minimum and maximum settings. Note: 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...

  • Page 46

    5-1 1 2 3 4 5 6 7 8 9 10 11 ebu19200 pre-operation checks ebu19220 pre-operation check list before operating this atv, be sure to check the items listed in the following table. Note: the maintenance of some items in the table has to be performed by a yamaha dealer. Refer to the “periodic maintenance...

  • Page 47

    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 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 sy...

  • Page 48

    5-3 1 2 3 4 5 6 7 8 9 10 11 warning ewb00480 always inspect your atv each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual. Failure to inspect increases the possibility of an accident...

  • Page 49

    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 4-8.) 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 50

    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 8-32.) 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 51

    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/kt341 radial size: at21 x 7-10 type: tubeless rear: manufacturer/model: dunlop/kt355a radial size: at20 x 10-9 type: tubeless ● the tires should be s...

  • Page 52

    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 53

    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 54

    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 55

    6-2 1 2 3 4 5 6 7 8 9 10 11 position (1): ● cold engine start with ambient temperature be- low 5 °c (40 °f). Position (2): ● cold engine start with ambient temperature be- tween 0 °c (30 °f) and 30 °c (90 °f). Position (3): ● cold engine start with ambient temperature above 25 °c (80 °f). Ambient te...

  • Page 56

    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...

  • Page 57

    6-4 1 2 3 4 5 6 7 8 9 10 11 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. Open the throttle gradually and at the same time, release the clutc...

  • Page 58

    6-5 1 2 3 4 5 6 7 8 9 10 11 the transmission. ● always use the clutch when changing gears. The engine, transmission and drive train are not designed to withstand the shock of forced shifting and can be damaged by shift- ing without using the clutch. Ebu20670 engine break-in there is never a more imp...

  • Page 59

    6-6 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

    6-7 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

    6-8 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

    7-1 1 2 3 4 5 6 7 8 9 10 11 ebu21141 riding your atv.

  • Page 63

    7-2 1 2 3 4 5 6 7 8 9 10 11 ebu21611 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

    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

    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

    7-5 1 2 3 4 5 6 7 8 9 10 11 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 follow the inspection and main- tenance procedures and schedules described i...

  • Page 67

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    8-1 1 2 3 4 5 6 7 8 9 10 11 ebu28781 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

    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

    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 87

    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 88

    8-5 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 89

    8-6 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 molybdenum disulfide grease. √ √ √ 11 * upper and lower arm pivots ● lubricate with lithium-soap-based grease. √ √ √ 12 drive chain ● check chain slack and a...

  • Page 90

    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 91

    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 92

    8-9 1 2 3 4 5 6 7 8 9 10 11 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 the panel needs to be removed and installed. Ebu23180 panel a to remove the panel 1. Remove th...

  • Page 93

    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. Ebu23241 checking the spark plug the spark plug is an important engine component, which is easy to check. Since heat and deposi...

  • Page 94

    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 4-11.) 2. Remove the bolts and the quick fastener screws shown. 3. Rem...

  • Page 95

    8-12 1 2 3 4 5 6 7 8 9 10 11 7. Remove the spark plug cap. 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. T...

  • Page 96

    8-13 1 2 3 4 5 6 7 8 9 10 11 kit. To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medi- um-to-light tan (the ideal color when the atv is ridden normally). Note: if the spark plug shows a distinctly different color, the engine could be ...

  • Page 97

    8-14 1 2 3 4 5 6 7 8 9 10 11 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Note: if a torque wrench is not available whe...

  • Page 98

    8-15 1 2 3 4 5 6 7 8 9 10 11 to check the engine oil level 1. Place the atv on a level surface. 2. Start the engine, warm it up until the engine oil has reached a normal temperature of 40 °c (104 °f), let it continue to idle for ten seconds or more, and then turn the engine off. Note: to achieve the...

  • Page 99

    8-16 1 2 3 4 5 6 7 8 9 10 11 note: when adding oil, be careful not to overfill the en- gine oil tank; the oil level rises faster starting from the half-level-portion on the dipstick. 6. Insert the dipstick into the engine oil tank filler hole, and then tighten the engine oil tank filler cap. Caution...

  • Page 100

    8-17 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. 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, ...

  • Page 101

    8-18 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. 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 spec...

  • Page 102

    8-19 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 the 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 eng...

  • Page 103

    8-20 1 2 3 4 5 6 7 8 9 10 11 do not use oils labeled “energy conserv- ing ii” or higher. ● make sure that no foreign material enters the crankcase. 15. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and...

  • Page 104

    8-21 1 2 3 4 5 6 7 8 9 10 11 3. If the coolant is at or below the minimum level mark, remove panel a. (see page 8-9.) 4. Remove the reservoir cap, add coolant or dis- tilled water to the maximum level mark, install the reservoir cap, and then install the panel. Caution: ecb00400 ● if coolant is not ...

  • Page 105

    8-22 1 2 3 4 5 6 7 8 9 10 11 removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always place a thick rag over the cap when opening. Allow any remaining pressure to escape before completely removing the cap. 1. Place the atv on a level surface. 2. Remove p...

  • Page 106

    8-23 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 107

    8-24 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 108

    8-25 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 and washer. 5. Remove the wing bolt and washer from the air filter element. 6. Remove the sponge material from the air filter element frame. 1. Air filter case cover 2. Air filter case ...

  • Page 109

    8-26 1 2 3 4 5 6 7 8 9 10 11 7. 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 110

    8-27 1 2 3 4 5 6 7 8 9 10 11 12. Install the washer onto the air filter element frame, and then insert the wing bolt into the hole in the air filter element frame. Caution: ecb00451 be sure to install the washer with the bent edge facing outward as shown. 13. Insert the air filter element into the a...

  • Page 111

    8-28 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 112

    8-29 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 113

    8-30 1 2 3 4 5 6 7 8 9 10 11 tenance. Caution: ecb00480 the carburetor has been set and extensively tested at the yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performance of or damage to the engine. Ebu24030 checking the engine idling speed a sp...

  • Page 114

    8-31 1 2 3 4 5 6 7 8 9 10 11 3. Tighten the locknut. Ebu24060 valve clearance the valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a yamaha dealer at the inter- vals specified in the ...

  • Page 115

    8-32 1 2 3 4 5 6 7 8 9 10 11 note: the wheels need to be removed to check the brake pads. (see page 8-50.) ebu27721 rear brake pads each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear...

  • Page 116

    8-33 1 2 3 4 5 6 7 8 9 10 11 front brake rear brake note: to check the rear brake fluid level, remove the seat. (see page 4-11.) if the rear brake fluid level is low, replenish as fol- lows. 1. Remove the brake fluid reservoir bracket bolt. 1. Minimum level mark 1 1. Minimum level mark 1.

  • Page 117

    8-34 1 2 3 4 5 6 7 8 9 10 11 2. Pull the brake fluid reservoir out to the side as shown. 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 flu...

  • Page 118

    8-35 1 2 3 4 5 6 7 8 9 10 11 6. Install the brake fluid reservoir bracket bolt. Observe these precautions: ● when checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causin...

  • Page 119

    8-36 1 2 3 4 5 6 7 8 9 10 11 ebu24390 checking the front brake lever free play the brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake lever should have a free play of zero mm (zero in) as shown. If the free play is incorrect,...

  • Page 120

    8-37 1 2 3 4 5 6 7 8 9 10 11 warning ewb02110 operating with improperly serviced or adjust- ed brakes could cause loss of braking ability, which could lead to an accident. After servicing: ● make sure the brakes operate smoothly and that the brake pedal position is correct. ● make sure the brakes do...

  • Page 121

    8-38 1 2 3 4 5 6 7 8 9 10 11 parking brake lever to the right. 2. Fully loosen the locknut and the adjusting bolt at the rear brake caliper. 3. Loosen the locknut on the brake cable. 4. Turn the adjusting nut on the brake cable in di- rection (a) to increase the cable length, and in direction (b) to...

  • Page 122

    8-39 1 2 3 4 5 6 7 8 9 10 11 ebu24740 brake light switches the operation of the brake light switches must be checked and, if necessary, adjusted at the inter- vals specified in the periodic maintenance and lu- brication chart. The brake light switch for the brake pedal can be adjusted as follows, bu...

  • Page 123

    8-40 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 124

    8-41 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 125

    8-42 1 2 3 4 5 6 7 8 9 10 11 warning ewb02130 inspect cables frequently and replace if dam- aged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could re- strict the operation of controls and lead to an accident or injury. Ebu24921 chec...

  • Page 126

    8-43 1 2 3 4 5 6 7 8 9 10 11 ebu24931 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 ebu24962 checking the wheel hub bearings the front and rear wh...

  • Page 127

    8-44 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 recommended lubricant: lithiu...

  • Page 128

    8-45 1 2 3 4 5 6 7 8 9 10 11 right side ebu25222 battery this model is equipped with a sealed-type (mf) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections. Caution: ecb006...

  • Page 129

    8-46 1 2 3 4 5 6 7 8 9 10 11 to store the battery 1. If the atv will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check it at least once a month and ful- ly charge it if ne...

  • Page 130

    8-47 1 2 3 4 5 6 7 8 9 10 11 the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Warning ewb02171 always use a fuse of the specified rating, and never use a substitute object in place of the proper fuse. An improper fuse...

  • Page 131

    8-48 1 2 3 4 5 6 7 8 9 10 11 4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the defective 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 132

    8-49 1 2 3 4 5 6 7 8 9 10 11 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. Thoroughly clean off any dirt and finger- prints on the head...

  • Page 133

    8-50 1 2 3 4 5 6 7 8 9 10 11 ebu25580 replacing the tail/brake light bulb if the tail/brake light bulb burns out, have a yamaha dealer replace it. Ebu25650 removing a wheel 1. Loosen the wheel nuts. Front rear 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the...

  • Page 134

    8-51 1 2 3 4 5 6 7 8 9 10 11 front 2. Lower the atv to the ground. 3. Tighten the wheel nuts to the specified torques. Ebu25740 troubleshooting although yamaha atvs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compre...

  • Page 135

    8-52 1 2 3 4 5 6 7 8 9 10 11 ebu25781 troubleshooting charts starting problems or poor engine performance check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compression. Operate the electric ...

  • Page 136

    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

    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

    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. Ebu25932 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a...

  • Page 139

    9-3 1 2 3 4 5 6 7 8 9 10 11 with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. 6. Lubricate all control cables and the pivoting points of all levers and pedals. 7. Check and, if necessary, correct the tire air pressure, and then block...

  • Page 140

    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 141

    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 142

    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 143

    10-4 1 2 3 4 5 6 7 8 9 10 11 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: swingarm (link suspension) spr...

  • Page 144

    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

    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 146

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning............................................ 8-24 b battery.......................................................................... 8-45 brake and clutch levers, checking and lubricatin...

  • Page 147

    L label locations ................................................................2-1 light switch .....................................................................4-3 m main switch .....................................................................4-1 maintenance and lubrication chart ..........

  • Page 148

    Printed in japan 2007.04-0.8x1 ! (e) yamaha motor co., ltd. Printed on recycled paper.