Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM45FXV 3C2-F8199-60...
Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2005.08-0.9×2 CR (E,F,S)
Page 3 OWNER’S MANUAL YFM45FXV 3C2-F8199-60-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 driving Periodic maintenance and lubrication in reverse ........... 6-3 chart ............8-3 Engine break-in ..........
Page 10 Axle boots ..........8-42 SPECIFICATIONS ........10-1 Brake light switches ......... 8-42 Checking and lubricating the cables ..8-43 CONSUMER INFORMATION.......11-1 Checking and lubricating the front and rear Identification numbers .......11-1 brake levers ..........8-43 Checking and lubricating the brake pedal ............8-44 Checking the wheel bearings ....
Page 11: Safety Information
EBU17430 SAFETY INFORMATION EBU17531 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park- AN ATV IS NOT A TOY AND CAN BE HAZARD- ing lots and paved streets. OUS TO OPERATE. An ATV handles differently Never operate an ATV on any paved street, from other vehicles including motorcycles and paved road or motorway.
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. Tail/brake light ring 2. Spark plug 2. Fuel cock 3. Rear brake fluid reservoir 3. Air filter case 4. Radiator cap 4. Fuses 5.
Page 19: Controls And Instruments
EBU17712 Controls and instruments 1. Rear brake lever 2. Left handlebar switches 3. Starter (choke) 4. Drive select lever 5. Main switch 6. Speedometer unit 7. Fuel tank cap 8. On-Command four-wheel-drive switch 9. Front brake lever 10.Throttle lever NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual.
Page 20: Instrument And Control Functions
EBU17730 INSTRUMENT AND CONTROL FUNCTIONS EBU17770 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights, meter lighting and taillight come on when the light switch is on, and the engine can be started.
Page 21: Indicator Lights And Warning Light
” This indicator comes on when the 2WD/4WD NOTE: switch is set to the 4WD position. If the indicator light flashes or the speedometer 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
EBU18060 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. EBU18160 Light switch “ /OFF” Set this switch to “ ”...
Page 24 EBU26600 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
EBU18390 Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the 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) “ ” EBU26370 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- Insert the projections on the front of the seat into partment, be sure to wrap them in a plastic bag so the seat holders and push down on the seat at the 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...
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 assembly 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, 8-36, 8-37, 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 adjust it.
Page 40: Throttle Lever
• Check and adjust tire pressures when the The tires listed below have been approved tires are cold. by Yamaha Motor Manufacturing Corpora- • Tire pressures must be equal on both tion of America for this model. Other tire sides.
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 kPa (5.8 psi) (0.40 kgf/cm²) Rear 40 kPa (5.8 psi) (0.40 kgf/cm²) Minimum: Front 37 kPa (5.3 psi) (0.37 kgf/cm²) Rear 37 kPa (5.3 psi) (0.37 kgf/cm²) Maximum: 1. Tire wear limit Front 43 kPa (6.2 psi) (0.43 kgf/cm²) EBU19840 Chassis fasteners Rear...
Page 43: Operation
4. Shift the drive select lever into the neutral or accident or injury. If there is a control or func- park position. The corresponding indicator tion you do not understand, ask your Yamaha light should come on, if it does not come on, dealer.
Page 44 5. Use the starter (choke) in reference to the fig- AMBIENT TEMP./STARTER (CHOKE) POSI- ure: TION Position (1): Cold engine start with ambient temperature below 5 °C (40 °F). Position (2): Cold engine start with ambient temperature between 0 °C (30 °F) and 30 °C (90 °F). Position (3): Cold engine start with ambient temperature above 25 °C (80 °F).
Page 45: Starting A Warm Engine
7. If the engine is started with the starter (choke) EBU20460 Operating the drive select lever and in position (1), the starter (choke) should be driving in reverse returned to position (2) to warm up the engine. ECB00170 If the engine is started with the starter (choke) CAUTION: in position (2), keep the starter (choke) in this Before shifting, stop the ATV, otherwise the...
Page 46 NOTE: should come on. If the indicator light does not 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. 1. Bring the ATV to a complete stop.
Page 47: Engine Break-In
There is never a more important period in the life of engine break-in period, immediately have a your engine than the first 20 hours of riding. For Yamaha dealer check the ATV. this reason, you should read the following material carefully.
Page 48: Parking On A Slope
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 qual-...
Page 49 Choose a genuine Yamaha ac- Never exceed the weight limits shown. An over- cessory, or one that is equivalent in design and loaded ATV can be unstable. quality. MAXIMUM LOADING LIMIT Accessories should be rigidly and securely ATV loading limit (total weight of rider, cargo, mounted.
Page 50 Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. 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.
Page 51: Riding Your Atv
EBU21140 RIDING YOUR ATV...
Page 52: Getting To Know Your Atv
EBU26572 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. EWB01810 WARNING Maintain 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 - the ATV may tip over on top of you.
Page 75: Periodic Maintenance And Minor Repair
EBU21650 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. √ √ Differential 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 EBU26410 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
EBU23210 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 defective. Do not attempt to di- agnose such problems yourself. Instead, 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 in 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 a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- erwise the effectiveness of the coolant will be reduced.
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 0.25 L (0.26 US qt) (0.22 Imp.qt) NOTE: ECB00400 If any leakage is found, have a Yamaha dealer CAUTION: check the cooling system. If coolant is not available, use distilled water 16. Install the cowling. or soft tap water instead. Do not use hard wa- 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: V-Belt Cooling Duct Check Hose
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: V-Belt Case Drain Plug
If water drains from the V-belt case after removing most carburetor adjustments should be left to a the plug, have a Yamaha dealer check the ATV as Yamaha dealer, who has the necessary profes- the water may affect other engine parts.
Page 108: 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 109: 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. 8-35...
Page 110: 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 111: Checking The Brake Fluid Level
EBU26470 Checking the brake fluid level Front brake 1. Wear indicator groove NOTE: The wheels need to be removed to check the 1. Minimum level mark brake pads. (See page 8-51.) 8-37...
Page 112 However, if the pads for wear and the brake system for leakage. brake fluid level goes down suddenly, have a NOTE: Yamaha dealer check the cause. To check the rear brake fluid level, remove cowling B. (See page 8-8.) 8-38...
Page 113: Changing The Brake Fluid
EBU24290 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the peri- odic maintenance and lubrication chart. In addi- tion, have the oil seals of the master cylinders and...
Page 114: Adjusting The Rear Brake Lever Free Play And Checking The Brake Pedal Position
EBU26491 Adjusting the rear brake lever free play and checking the brake pedal position The brake lever free play must be adjusted and brake pedal position must be checked and, if nec- essary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
Page 115 The top of the brake pedal should be positioned 67.0–77.0 mm (2.64–3.03 in) above the top of the footboard bracket. If the brake pedal position is in- correct, have a Yamaha dealer adjust it. 1. Locknut 2. Brake lever free play adjusting bolt 3.
Page 116: Axle Boots
EBU24230 adjusted as follows, but the other brake light Axle boots switches should be adjusted by a Yamaha dealer. The axle boots must be checked for damage at the 1. Remove panel A. (See page 8-8.) intervals specified in the periodic maintenance and lubrication chart.
Page 117: Checking And Lubricating The Cables
Lithium-soap-based grease (all-purpose cables and cable ends should be lubricated if nec- grease) essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil 8-43...
Page 118: Checking And Lubricating The Brake Pedal
Yamaha dealer check the wheel NOTE: bearings. To access the brake pedal pivot, remove panel A.
Page 119: Lubricating The Knuckle Pivots
Recommended lubricant: Recommended lubricant: Lithium-soap-based grease Lithium-soap-based grease EBU25060 EBU25221 Lubricating the knuckle pivots Battery The knuckle pivots must be lubricated at the inter- This model is equipped with a sealed-type (MF) vals specified in the periodic maintenance and lu- battery, which does not require any maintenance.
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
Yamaha dealer charge your bat- tery. EBU25321 Replacing a fuse 1. Headlight fuse 2. Ignition fuse 3. Auxiliary DC jack fuse (for optional auxiliary DC jack) 4. Four-wheel-drive motor fuse 5. Signaling system fuse 6.
Page 122: Replacing A Headlight Bulb
3. Turn the key to “ON” and turn on the electrical Specified fuses: circuits to check if the devices operate. Main fuse: 4. If the fuse immediately blows again, have a 30.0 A Yamaha dealer check the electrical system. Headlight fuse: EBU25540 15.0 A Replacing a headlight bulb Ignition fuse: If a headlight bulb burns out, replace it as follows.
Page 123 3. Remove the defective bulb from the headlight unit by pulling it out. EWB02220 WARNING A headlight bulb is hot when it is on and imme- diately after it is turned off. Wait for the bulb to cool before touching or removing it. You can be burned or a fire could start if the bulb touch- es something flammable.
Page 124: Adjusting A Headlight Beam
CAUTION: bulb, and the bulb life will be adversely affect- It is advisable to have a Yamaha dealer make ed. Thoroughly clean off any dirt and finger- this adjustment. prints on the headlight bulb using a cloth moistened with alcohol or thinner.
Page 125: Replacing The Tail/Brake Light Bulb
EBU25600 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Remove the lens by removing the screws. 1. Tail/brake light bulb 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops.
Page 126: Installing A Wheel
Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Nut 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 1.
Page 127: Troubleshooting
The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- 1. Tapered nut rience, and know-how to service the ATV properly.
Page 128: 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 129 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 130: 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 131: 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 132 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 133: Specifications
EBU25960 SPECIFICATIONS Dimensions: Cylinder arrangement: Forward-inclined single cylinder Overall length: Displacement: 1978 mm (77.9 in) 421.0 cm³ (25.69 cu.in) Overall width: Bore × stroke: 1063 mm (41.9 in) 84.5 × 75.0 mm (3.33 × 2.95 in) Overall height: Compression ratio: 1095 mm (43.1 in) 10.00 :1 Seat height:...
Page 134 Engine oil: Differential gear oil: Type: Type: SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 SAE80 API GL-4 Hypoid gear oil or SAE20W40 or SAE20W50 Quantity: 0.35 L (0.37 US qt) (0.31 Imp.qt) Cooling system: -20˚ -10˚ 0˚ 20˚ 30˚ 40˚ 50˚C 10˚...
Page 135 Clutch: Manufacturer/model: MAXXIS/M937 Clutch type: Rear tire: Wet, centrifugal automatic Transmission: Type: Tubeless Primary reduction system: Size: V-belt AT23 x 10R12 Secondary reduction system: Manufacturer/model: Shaft drive MAXXIS/M938 Secondary reduction ratio: 39/24 × 24/18 × 33/9 (7.944) Loading: Transmission type: Maximum load: V-belt automatic 100.0 kg (220 lb)
Page 136 Front wheel: Rear suspension: Wheel type: Type: Panel wheel Swingarm Rim size: Spring/shock absorber type: 12 x 6.0AT Coil spring/oil damper Rear wheel: Wheel travel: 180.0 mm (7.09 in) Wheel type: Electrical system: Panel wheel Rim size: Ignition system: 12 x 7.5AT DC.
Page 137 Park indicator light: Four-wheel-drive indicator: Fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Ignition fuse: 10.0 A Auxiliary DC jack fuse: 10.0 A Backup fuse: 10.0 A Four-wheel-drive motor fuse: 3.0 A 10-5...
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 ..8-36 Axle boots ..............
Page 141 Specifications ............... 10-1 Speed limiter ..............4-6 Key identification number ..........11-1 Speedometer unit ............4-3 Knuckle pivots, lubricating ........... 8-45 Starter (choke) ............. 4-11 Knuckle shafts, lubricating ........... 8-45 Start switch ..............4-4 Steering shaft, lubricating ..........8-45 Label locations ............... 2-1 Storage ................
Page 142 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2005.08-0.9×1 CR...

Yamaha WOLVERINE YFM45FXV Owner's Manual

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