Yamaha WOLVERINE YFM45FXW Owner's Manual
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Yamaha WOLVERINE YFM45FXW Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM45FXW
3C2-F8199-61

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Summary of Contents for Yamaha WOLVERINE YFM45FXW

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM45FXW 3C2-F8199-61...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2006.07-0.3×1 CR (E,F,S)
  • Page 3 OWNER’S MANUAL YFM45FXW 3C2-F8199-61-E0...
  • Page 5 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 degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • 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: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or...
  • Page 7 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.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Starter (choke) ..........4-11 Seat ............4-12 LOCATION OF THE WARNING AND Storage compartment .......4-13 SPECIFICATION LABELS ......2-1 Adjusting the front shock absorber assemblies ..........4-14 DESCRIPTION ..........3-1 Adjusting the rear shock absorber Left view ............
  • Page 9 OPERATION ..........6-1 PERIODIC MAINTENANCE AND MINOR Starting a cold engine ........ 6-1 REPAIR ............8-1 Starting a warm engine ......6-3 Owner’s manual and tool kit .......8-1 Operating the drive select lever and Periodic maintenance and lubrication driving in reverse ........6-3 chart ............8-3 Engine break-in ..........
  • Page 10 Adjusting the rear brake lever free play SPECIFICATIONS ........10-1 and checking the brake pedal position ... 8-40 Axle boots ..........8-42 CONSUMER INFORMATION.......11-1 Brake light switches ......... 8-43 Identification numbers .......11-1 Checking and lubricating the cables ..8-43 Checking and lubricating the front and rear brake levers ........

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION EBU17534 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 12 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 13 hill. If you stall or roll backwards, follow the spe- Always be sure there are no obstacles or people cial procedure for braking described in this man- behind you when you operate in reverse. When ual. Dismount on the uphill side or to a side if it is safe to proceed in reverse, go slowly.
  • Page 14 When transporting the ATV in another vehi- EWB00070 WARNING cle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel Always operate your ATV in an area with ade- may leak out of the carburetor or fuel tank. quate ventilation.

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.

  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly spring preload adjusting 1. Spark arrester ring 2. Tail/brake light 2. Fuel cock 3. Battery 3. Air filter case 4. Spark plug 4. Fuses 5. Rear brake fluid reservoir 5.

  • Page 19: Controls And Instruments

    EBU17712 NOTE: Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Left handlebar switches 3. Starter (choke) 4. Drive select lever 5. Main switch 6. Speedometer unit 7.

  • Page 20: Instrument And Control Functions

    EBU17731 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

  • Page 21: Indicator Lights And Warning Light

    This indicator comes on when the On-Command NOTE: four-wheel-drive switch is set to the “4WD” posi- If the indicator light flashes or the speedometer tion. does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit.

  • Page 22: Speedometer Unit

    The speedometer unit is equipped with the follow- NOTE: ing: Due to the synchronizing mechanism in the differ- a speedometer (which shows the riding speed) ential gear case, the indicator may not come on un- an odometer (which shows the total distance til the ATV starts moving.

  • Page 23: Handlebar Switches

    EBU18061 EBU18100 Handlebar switches Start switch “ ” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18151 Light switch “ /OFF” Set this switch to “ ”...
  • Page 24 EBU28220 On-Command four-wheel-drive switch “2WD”/“4WD” This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice-versa. Select the appropriate drive according to the ter- rain and the conditions. “2WD” (two-wheel drive): Power is supplied to the rear wheels.

  • Page 25: Throttle Lever

    Correct the problem be- the throttle lever. fore riding the ATV or consult a Yamaha dealer. EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 26: Front Brake Lever

    EBU18391 Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip. 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in) 3.

  • Page 27: Drive Select Lever

    EBU18621 Drive select lever The drive select lever is used to shift your ATV into the forward, neutral, reverse and park positions. See the “Operating the drive select lever and driv- ing in reverse” section on page 6-3 for the drive se- lect lever operation.

  • Page 28: Fuel

    1. Fuel tank cap 1. Fuel level 2. Fuel tank filler tube EBU18750 Fuel Recommended fuel: Make sure that there is sufficient fuel in the tank. UNLEADED GASOLINE ONLY Fill the fuel tank to the bottom of the filler tube as For Europe: Regular unleaded gasoline only shown.

  • Page 29: Fuel Cock

    EBU18820 NOTE: Fuel cock If knocking or pinging occurs, use a different brand The fuel cock supplies fuel from the tank to the car- of gasoline or higher octane grade. buretor while also filtering it. The fuel cock lever positions are explained as fol- ECB00070 lows and shown in the illustrations.

  • Page 30: Starter (Choke)

    1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.

  • Page 31: Seat

    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. 1. Seat 1. Starter (choke) “ ” EBU26981 Seat To remove the seat Push the seat lock lever backward and pull up the seat at the rear.

  • Page 32: Storage Compartment

    To install the seat When storing any documents in the storage com- Fit the slot in the seat onto the projection on the partment, be sure to wrap them in a plastic bag so front cowling, insert the projections on the front of that they will not get wet.

  • Page 33: Adjusting The Front Shock Absorber Assemblies

    1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha 1. Storage compartment drain plug dealer to make this adjustment. EBU18990 Adjusting the front shock absorber as-...

  • Page 34: Adjusting The Rear Shock Absorber Assembly

    EWB00400 WARNING Always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. EBU19020 Adjusting the rear shock absorber as- sembly 1.
  • Page 35 1. Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: Maximum (hard): 4-16...

  • Page 36: Pre-Operation Checks

    Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 37 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check lever free play, and adjust if necessary. Rear brake • Check brake pads for wear, and replace if necessary. 5-4, 8-37, 8-38, 8-40 •...

  • Page 38: Fuel

    EBU19540 EBU19600 Fuel Differential gear oil Make sure that there is sufficient fuel in the tank. Make sure that the differential gear oil is at the (See page 4-9.) specified level. Add oil as necessary. (See page EWB00520 8-23.) WARNING EBU19630 Do not overfill the fuel tank.

  • Page 39: Front And Rear Brakes

    Check that there is no free play in the front brake ly inward, there may be a leak in the brake system. lever. If there is free play, have a Yamaha dealer If there is any leakage, the brake system should be check the brake system.

  • Page 40: Throttle Lever

    Throttle lever Manufacturer/model: Check the operation of the throttle lever. It must MAXXIS/M938 open smoothly and spring back to the idle position Size: when released. Have a Yamaha dealer correct if AT23 x 10R12 necessary. Type: Tubeless EBU19811 The tires should be set to the recommended...

  • Page 41: Measuring The Tire Pressure

    • Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (36 psi) (2.5 kgf/cm²) Rear: 250 kPa (36 psi) (2.5 kgf/cm²) Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully.

  • Page 42: Tire Wear Limit

    Recommended pressure: Front 40.0 kPa (5.8 psi) (0.400 kgf/cm²) Rear 40.0 kPa (5.8 psi) (0.400 kgf/cm²) Minimum: Front 37.0 kPa (5.3 psi) (0.370 kgf/cm²) Rear 37.0 kPa (5.3 psi) (0.370 kgf/cm²) Maximum: 1. Tire wear limit Front 43.0 kPa (6.2 psi) (0.430 kgf/cm²) EBU19840 Chassis fasteners Rear...

  • Page 43: Operation

    The corresponding indicator accident or injury. If there is a control or func- light should come on, if it does not come on, tion you do not understand, ask your Yamaha have a Yamaha dealer check the electrical cir- dealer.
  • Page 44 4. Use the starter (choke) in reference to the fig- 5. Apply the rear brake lever. ure: 6. Completely close the throttle lever and start Position (1): the engine by pushing the start switch. Cold engine start with ambient temperature NOTE: below 5 °C (40 °F).

  • Page 45: Starting A Warm Engine

    NOTE: NOTE: The engine is warm when it responds normally to Make sure that the drive select lever is completely the throttle with the starter (choke) turned off. shifted into position. EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm.
  • Page 46 If the indicator light does not NOTE: The drive select lever cannot be shifted into or from come on, have a Yamaha dealer check the elec- reverse or park without applying the brake pedal. trical circuit. Due to the synchronizing mechanism in the en- 1.

  • Page 47: Engine Break-In

    320 km (200 mi) or 20 engine break-in period, immediately have a hours of riding. For this reason, you should read Yamaha dealer check the ATV. the following material carefully. Since the engine is brand new, do not put an ex-...

  • Page 48: Accessories And Loading

    3. With the brake pedal applied, shift the drive may also be available on the market. However, select lever to the park position. it is not possible for Yamaha to test all non- Yamaha accessories, nor control over their qual- ity or suitability. Choose a genuine Yamaha ac- cessory, or one that is equivalent in design and quality.
  • Page 49 could make steering difficult, an accessory that If you are carrying cargo and towing a trailer, in- limits your ability to move around on the seat, or clude the tongue weight in the maximum ATV one that limits your view. load limit.
  • Page 50 EWB00820 WARNING Never exceed the stated load capacity for this ATV. Overloading this ATV or carrying or tow- ing cargo improperly could cause changes in ATV handling which could lead to an accident. Cargo should be properly distributed and se- curely attached.

  • Page 51: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 52: Getting To Know Your Atv

    EBU26574 Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum performance until GETTING TO KNOW YOUR ATV you are totally familiar with the ATV’s handling and This ATV is intended for recreational use by expe- performance characteristics.
  • Page 53 Not recommended for children under 16 years This ATV is designed to carry operator and car- of age. go only – passengers prohibited. EWB01390 EWB01400 WARNING WARNING A child under 16 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 90 cc.
  • Page 54 Apparel Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet...
  • Page 55 EWB01410 WARNING Never operate this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 56 in the Owner’s Manual. Failure to inspect the Speed limiter ATV before operating or failure to properly For riders less experienced with this model, the maintain the ATV increases the possibility of throttle lever housing is equipped with a speed lim- an accident or equipment damage.
  • Page 57 Loading and accessories Always follow the instructions in your Own- As originally equipped, this ATV is not designed to er’s Manual for carrying cargo or pulling a carry cargo or tow a trailer. If you choose to add ac- trailer. cessories so that you can carry cargo or tow a trail- er, you must use common sense and good During operation...
  • Page 58 All parts and you or cause an accident. accessories added to this ATV should be gen- uine Yamaha or equivalent components de- Avoid wheelies and jumping. You may lose control signed for use on this ATV and should be of the ATV or overturn.

  • Page 59: Be Careful Where You Ride

    Do not park the ATV during or after operation EWB01510 WARNING in a place where others might be likely to touch it. Always avoid paved surfaces, including side- Do not operate, idle, or park the ATV in dry walks, driveways, parking lots and streets. grass, dry ground cover, or combustible ma- ATVs are designed for use on unpaved surfac- terials.
  • Page 60 While riding on unpaved public streets or roads Know the terrain where you ride. Ride cautiously in may be legal in your area, such operation can in- unfamiliar areas. Stay alert for holes, rocks, or crease the risk of collision with other vehicles. roots in the terrain, and other hidden hazards Watch carefully for other vehicles.
  • Page 61 EWB01540 When riding in an area where you might not easily WARNING be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket Do not operate on excessively rough, slippery as a trailer hitch. or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.

  • Page 62: Turning Your Atv

    With the engine idling, return the starter (choke) to the closed position, and shift the drive select lever into the forward position. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is ap- plied too abruptly, the front wheels may lift off the ground, resulting in a loss of directional control.
  • Page 63 EWB01570 WARNING Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions. As you approach a curve, slow down and begin to turn the handlebars in the desired direction.

  • Page 64: Climbing Uphill

    Improper riding procedures such as abrupt throttle EWB01580 WARNING changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the Never operate the ATV on hills too steep for the turn may cause the ATV to tip. If the ATV begins to ATV or for your abilities.
  • Page 65 Never go over the top of any hill at high EWB01600 WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never attempt to turn the ATV around on any of the hill. hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground.
  • Page 66 ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediately on the uphill side. EWB01811 WARNING Maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.

  • Page 67: Riding Downhill

    When this ATV is in 4WD, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the downhill side.

  • Page 68: Crossing A Slope

    Avoid going down a hill at an angle that to cross a sloping surface. Avoid slopes with slip- would cause the ATV to lean sharply to one pery surfaces or rough terrain that may upset your side. Go straight down the hill where possi- balance.

  • Page 69: Crossing Through Shallow Water

    Shift your weight to the uphill side of the EWB01640 WARNING ATV. Never operate this ATV in fast flowing water or 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.
  • Page 70 Test your brakes after leaving the water. Do not plug to drain any water that may have accumu- continue to ride your ATV without verifying that you lated. Wash the ATV in fresh water if it has been have regained proper braking ability. operated in salt water or muddy conditions.
  • Page 71 1. V-belt cooling duct check hose (left front side of ATV) 1. Storage compartment drain plug 1. Drive select lever box check hose 1. V-belt case drain plug 7-21...

  • Page 72: Riding Over Rough Terrain

    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.

  • Page 73: What To Do If

    On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control. WHAT TO DO IF... This section is designed to be a reference guide only.
  • Page 74 If your ATV can’t make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD –...

  • Page 75: Periodic Maintenance And Minor Repair

    EBU21654 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21670 otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with Safety is an obligation of the owner. Periodic in- maintenance work. spection, adjustment and lubrication will keep your...
  • Page 76 NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING Never modify this ATV through improper in-...

  • Page 77: Periodic Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours • Check operation and correct if necessary. • Check brake lever free play and adjust if neces- √ √...
  • Page 79 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Shock absorber as- • Check operation and correct if necessary. √ √ √ 15 * semblies • Check for oil leakage and replace if necessary. √...
  • Page 80 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours • Change. √ √ Final gear oil • Check ATV for oil leakage, and correct if neces- sary. •...
  • Page 81 EBU23070 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 82: Removing And Installing Cowlings And Panels

    EBU26401 Removing and installing cowlings and panels The cowlings and panels shown need to be re- moved to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed.
  • Page 83 1. Speedometer unit coupler 1. Bolt (left side) 4. Remove cowling A by removing the bolts, nuts and washers. 1. Bolt (right side) 1. Bolt...
  • Page 84 To install the cowling 3. Pull off the handlebar cover. 1. Connect the speedometer unit couplers. ECB00740 CAUTION: 2. Install cowling A by installing the bolts, nuts and washers. Do not disconnect the main switch coupler. 3. Install panel B. 4.
  • Page 85 5. Remove the cowling by removing the bolts. 1. Bolt (right side) 1. Bolt 6. Install the fuel tank cap by turning it clockwise. To install the cowling 1. Remove the fuel tank cap by turning it coun- terclockwise. 2. Install the cowling by installing the bolts. 3.
  • Page 86 EBU26411 Panel B To remove the panel Pull outward on the areas shown. Panel A To remove the panel Remove the bolt, and then take the panel off. 1. Panel B To install the panel Insert the tabs on the panel into the slots in cowling 1.
  • Page 87 1. Tab 1. Panel C 2. Slot 2. Bolt To install the panel Panel C Place the panel in the original position and install To remove the panel the bolts. Remove the bolts, and then take the panel off. Panel D To remove the panel Pull outward on the areas shown.

  • Page 88: Checking The Spark Plug

    EBU23211 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart.
  • Page 89 (the ideal color when the ATV is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-15...

  • Page 90: Engine Oil And Oil Filter Cartridge

    NOTE: 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. 4.
  • Page 91 1. Engine oil filler cap 1. Dipstick 2. Maximum level mark 6. Insert the dipstick into the filler hole (without 3. Minimum level mark screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the minimum and maximum level marks.
  • Page 92 To change the engine oil (with or without oil fil- NOTE: ter cartridge replacement) Skip steps 6–10 if the oil filter cartridge is not being 1. Place the ATV on a level surface. replaced. 2. Remove panel D. (See page 8-8.) 6.
  • Page 93 1. Oil filter wrench 1. O-ring NOTE: NOTE: An oil filter wrench is available at a nearby Yamaha Make sure that the O-ring is properly seated. dealer. 9. Install the new oil filter cartridge with an oil fil- 8. Apply a thin coat of engine oil to the O-ring of ter wrench, and then tighten it to the specified the new oil filter cartridge.
  • Page 94 12. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.43 US qt) (2.02 Imp.qt) With oil filter cartridge replacement: 2.40 L (2.54 US qt) (2.11 Imp.qt) 1.

  • Page 95: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified 1.
  • Page 96 To change the final gear oil 1. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 1. Final gear case guard 2.

  • Page 97: Changing The Differential Gear Oil

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, ECB00420 have a Yamaha dealer check and repair the ATV. CAUTION: In addition, the differential gear oil must be Be sure no foreign material enters the final changed as follows at the intervals specified in the gear case.
  • Page 98 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case. 1. Differential gear oil drain bolt 4. Install the drain bolt, and then tighten it to the specified torque.

  • Page 99: Coolant

    The differential gear case capacity is greater EBU23470 Coolant than the recommended oil quantity, therefore The coolant level should be checked before each the oil level cannot be accurately checked from ride. In addition, the coolant must be changed at the oil filler hole.
  • Page 100 1. Maximum level mark 1. Coolant reservoir cap 2. Minimum level mark Coolant reservoir capacity (up to the maximum 3. If the coolant is at or below the minimum level level mark): mark, remove the reservoir cap, add coolant 0.25 L (0.26 US qt) (0.22 Imp.qt) or distilled water to the maximum level mark, and then install the reservoir cap.
  • Page 101 If water has been added to the coolant, have 3. Place a container under the engine, and then a Yamaha dealer check the antifreeze con- remove the coolant drain bolt. (Use a trough tent of the coolant as soon as possible, oth-...
  • Page 102 6. Remove the coolant reservoir cap. 7. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the cool- ant reservoir. 1. Trough 4. Remove cowling A. (See page 8-8.) 5. Remove the radiator cap. 1. Coolant reservoir hose 8.
  • Page 103 Coolant reservoir capacity (up to the maxi- leakage. mum level mark): 0.25 L (0.26 US qt) (0.22 Imp.qt) NOTE: If any leakage is found, have a Yamaha dealer ECB00401 check the cooling system. CAUTION: 16. Install the cowling. If coolant is not available, use distilled water 17.

  • Page 104: Cleaning The Air Filter Element

    EBU23640 2. Remove the air filter case cover by unhooking Cleaning the air filter element the holders. The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas.
  • Page 105 1. Air filter element 1. Air filter element frame 2. Sponge material 4. Pull off the lock plate, and then remove the 3. Air filter element lock plate sponge material from the air filter element 5. Wash the sponge material gently but thor- frame.

  • Page 106: Cleaning The Spark Arrester

    ECB00440 manifold fittings for an air-tight seal. Tighten all fit- CAUTION: tings securely to avoid the possibility of unfiltered air entering the engine. Do not twist the sponge material when squeez- ing it. ECB00460 CAUTION: 7. Check the sponge material and replace it if damaged.
  • Page 107 1. Bolt 1. Tailpipe 2. Tailpipe cover 2. Spark arrester 3. Tap the tailpipe lightly, and then use a wire 4. Insert the tailpipe into the muffler and align the brush to remove any carbon deposits from the bolt holes. spark arrester portion of the tailpipe and inside 5.

  • Page 108: V-Belt Cooling Duct Check Hose

    If water drains from the V-belt case after removing be performed by the owner as part of routine main- the plug, have a Yamaha dealer check the ATV as tenance. the water may affect other engine parts.

  • Page 109: Adjusting The Engine Idling Speed

    NOTE: NOTE: If the specified idling speed cannot be obtained as The engine is warm when it quickly responds to the described above, have a Yamaha dealer make the throttle. adjustment. 2. Attach the tachometer to the spark plug lead.

  • Page 110: Adjusting The Throttle Cable Free Play

    The valve clearance changes with use, resulting in bolt in direction (b). 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 periodic maintenance and lu- brication chart. 8-36...

  • Page 111: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm Each rear brake pad is provided with wear indica- (0.04 in), have a Yamaha dealer replace the brake tor grooves, which allow you to check the brake pads as a set.

  • Page 112: Checking The Brake Fluid Level

    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 1. Wear indicator groove NOTE: The wheels need to be removed to check the brake pads.

  • Page 113: Changing The Brake Fluid

    To check the rear brake fluid level, remove cowling EBU24290 Changing the brake fluid B. (See page 8-8.) Have a Yamaha dealer change the brake fluid at Observe these precautions: the intervals specified in the NOTE after the peri- When checking the fluid level, make sure that odic maintenance and lubrication chart.

  • Page 114: Checking The Front Brake Lever Free Play

    (zero in) as shown. If the free Replacement of brake components requires play is incorrect, have a Yamaha dealer check the professional knowledge. These procedures brake system. should be performed by a Yamaha dealer.
  • Page 115 2. Brake lever free play adjusting bolt 3. Tighten the locknut. If the correct free play cannot be obtained, have a 1. Brake lever free play Yamaha dealer adjust it. 1. Loosen the locknut. NOTE: 2. Turn the brake lever free play adjusting bolt in...

  • Page 116: Axle Boots

    67.0–77.0 mm (2.64–3.03 in) above the top of the Replacement of brake components requires footboard bracket. If the brake pedal position is in- professional knowledge. These procedures correct, have a Yamaha dealer adjust it. should be performed by a Yamaha dealer. EBU24230 Axle boots...

  • Page 117: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. 1. Remove panel A. (See page 8-8.) NOTE: 1. Brake light switch The brake light switch is properly adjusted when 2.

  • Page 118: Checking And Lubricating The Front And Rear Brake Levers

    EWB02130 WARNING Inspect cables frequently and replace if dam- aged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could re- strict the operation of controls and lead to an accident or injury. EBU24911 Checking and lubricating the front and rear brake levers...

  • Page 119: Checking The Wheel Bearings

    There is no need to check the electrolyte or to add in a wheel hub or if a wheel does not turn smoothly, distilled water. Check and, if necessary, tighten the have a Yamaha dealer check the wheel bearings. battery lead connections. ECB00620...
  • Page 120 KEEP OUT OF REACH OF CHILDREN. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.

  • Page 121: Replacing A Fuse

    To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat- tery. 8-47...
  • Page 122 ECB00640 CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A 1. Headlight fuse Headlight fuse: 2.

  • Page 123: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Headlight bulb holder cover EBU25541 2. Remove the headlight bulb holder by pushing Replacing a headlight bulb it inward and turning it counterclockwise.
  • Page 124 3. Remove the defective bulb from the headlight ECB00650 CAUTION: unit by pulling it out. EWB02220 Do not touch the glass part of the headlight WARNING bulb to keep it free from oil, otherwise the A headlight bulb is hot when it is on and imme- transparency of the glass, the luminosity of the diately after it is turned off.

  • Page 125: Adjusting A Headlight Beam

    7. Adjust the headlight beam if necessary. EBU25560 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make 1. Headlight beam adjusting bolt this adjustment. EBU25600 Replacing the tail/brake light bulb To raise a headlight beam, turn the adjusting bolt in direction (a).

  • Page 126: Removing A Wheel

    3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. ECB00700 CAUTION: Do not overtighten the screws, otherwise the lens may break. EBU25650 Removing a wheel 1.

  • Page 127: Installing A Wheel

    4. Remove the wheel. EBU25700 Installing a wheel 1. Install the wheel and the nuts. NOTE: The arrow mark on the tire must point toward the rotating direction of the wheel. Tapered nuts are used for both the front and rear wheels.

  • Page 128: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 129: Troubleshooting Charts

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.
  • Page 130 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.

  • Page 131: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25880 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 132: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the brakes after washing. Apply the brakes several 2.
  • Page 133 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-45.

  • Page 134: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 10.00 :1 Overall length: Starting system: 1978 mm (77.9 in) Electric starter Overall width: Lubrication system: 1063 mm (41.9 in) Wet sump Overall height: Engine oil: 1095 mm (43.1 in) Seat height: Type: 840 mm (33.1 in) SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 Wheelbase: or SAE20W40 or SAE20W50...
  • Page 135 Engine oil quantity: Carburetor: Without oil filter cartridge replacement: Manufacturer: 2.30 L (2.43 US qt) (2.02 Imp.qt) MIKUNI With oil filter cartridge replacement: Type x quantity: 2.40 L (2.54 US qt) (2.11 Imp.qt) BSR33 x 1 Final gear oil: Spark plug (s): Type: Manufacturer/model: SAE80 API GL-4 Hypoid gear oil...
  • Page 136 Caster angle: Rear: 4.0 ° 37.0 kPa (5.3 psi) (0.370 kgf/cm²) Trail: Maximum: 19.3 mm (0.76 in) Front: Front tire: 43.0 kPa (6.2 psi) (0.430 kgf/cm²) Rear: Type: 43.0 kPa (6.2 psi) (0.430 kgf/cm²) Tubeless Front wheel: Size: AT23 x 8R12 Wheel type: Manufacturer/model: Panel wheel...
  • Page 137 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Neutral indicator light: Double wishbone Spring/shock absorber type: Reverse indicator light: Coil spring/oil damper Wheel travel: Coolant temperature warning light: 160 mm (6.3 in) Rear suspension: Park indicator light: Type: Swingarm On-Command four-wheel-drive indicator:...

  • Page 138: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 139 EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 140 INDEX Differential gear oil, changing ........8-23 Drive select lever ............4-8 Accessories and loading ..........6-6 Drive select lever and driving in reverse ......6-3 Air filter element, cleaning ..........8-30 Drive select lever safety system cable, adjusting ..8-37 Axle boots ..............
  • Page 141 Speed limiter ..............4-6 Speedometer unit ............4-3 Key identification number ..........11-1 Starter (choke) ............. 4-11 Start switch ..............4-4 Label locations ............... 2-1 Steering shaft, lubricating ..........8-45 Light switch ..............4-4 Storage ................9-2 Storage compartment ..........4-13 Main switch ..............
  • Page 142 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2006.07-0.3×1 CR...

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