Yamaha YFM45KDXK Owner's Manual
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Yamaha YFM45KDXK Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM45KDXK/YFM45KDHK
YFM45KPXK/YFM45KPLK
YFM45KPHK
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-32-08
BB5-F8199-11

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Summary of Contents for Yamaha YFM45KDXK

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45KDXK/YFM45KDHK YFM45KPXK/YFM45KPLK YFM45KPHK WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-32-08 BB5-F8199-11...
  • Page 2 EBU37021 Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your...
  • Page 3 YFM45KPLK / YFM45KPHK. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting 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 4 EBU17331 IMPORTANT MANUAL INFORMATION EBU17344 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: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 5 This ATV complies with all applicable off-road noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV. EBU17403 YFM45KDXK / YFM45KDHK / YFM45KPXK / YFM45KPLK / YFM45KPHK OWNER’S MANUAL ©2019 by Yamaha Motor Corporation, U.S.A.

  • Page 6: Table Of Contents

    Throttle lever..........4-8 EWB00012 WARNING Speed limiter..........4-8 Front brake lever......... 4-9 Indicates a hazardous situation which, if not Brake pedal and rear brake lever ....4-9 avoided, could result in death or serious injury. Drive select lever ........4-10 Fuel tank cap ..........
  • Page 7 Instruments, lights and switches ....5-6 PERIODIC MAINTENANCE AND ADJUSTMENT ..........8-1 OPERATION ........... 6-1 Owner’s Manual and tool kit....... 8-2 Starting the engine........6-1 Periodic maintenance chart: Emission Operating the drive select lever and control system .......... 8-3 driving in reverse........6-2 Periodic maintenance chart: General Engine break-in ...........
  • Page 8 U.S.A. 2015 AND LATER MODEL Lubricating the drive shaft universal ATV LIMITED WARRANTY ..... 11-6 joint ............8-50 YAMAHA EXTENDED SERVICE (Y.E.S.)... 11-8 Checking the stabilizer bushes ....8-50 INDEX ............12-1 Lubricating the rear knuckle pivots...8-51 Lubricating the steering shaft ....8-51 Battery............8-52...

  • Page 9: Location Of The Warning And Specification Labels

    EBU17661 LOCATION OF THE WARNING AND SPECIFICATION LABELS 8 9 10...
  • Page 10 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 re- placement label from your Yamaha dealer. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN Overloading this ATV or carrying cargo improperly can change CAUSE LOSS OF CONTROL.
  • Page 11 ( 6 0 0 k g f ) Overloading this ATV or carrying cargo improperly can change 5880 N 1322 handling, stability and braking performance and can lead to an ( 1 5 k g f ) accident. Never exceed the maximum rear cargo limit of : 176 lbs (80 kg) : 187 lbs.
  • Page 12 ANSI/SVIA 1-2017 and is subject to an approved LOCATE AND READ OWNER’S MANUAL. ATV action plan submitted by YAMAHA and on file FOLLOW ALL INSTRUCTIONS AND WARNINGS. with the U.S. Consumer Product Safety Commission. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CORPORATION U.S.A.

  • Page 13: Safety Information

    EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Never allow a child under age 16 to operate an EBU27236 ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 14  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 15  Always use proper procedures if you stall or roll reduced stopping ability. Test your brakes after backwards when climbing a hill. To avoid stall- leaving water. If necessary, apply them several ing, use the proper gear range and maintain a times to let friction dry out the linings.
  • Page 16 In the event of an accident tention. If necessary, contact your riding party 1. If serious injuries are incurred, you may be or local authorities to let them know where safer staying next to your vehicle; it may you are and what has happened. shield you from oncoming riders.
  • Page 17 This im- While you may find aftermarket products similar in proper position limits the freedom of movement design and quality to genuine Yamaha accesso- of the operator and may limit control ability, ries, recognize that some aftermarket accessories...
  • Page 18  Do not run engine outdoors where engine EWB00073 WARNING exhaust can be drawn into a building through openings such as windows and doors. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, FOR MORE INFORMATION ABOUT ATV SAFE- a deadly gas.

  • Page 19: Description

    EBU17681 DESCRIPTION EBU17691 EBU17701 Left view Right view 3 4 5 1. Radiator cap 1. Spark arrester 2. Air filter 2. Storage compartment and tool kit 3. Battery 3. Fuel tank cap 4. Fuses 4. Spark plug 5. Brake/tail light 5.

  • Page 20: Controls And Instruments

    EBU17715 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Drive select lever 4. Display unit 5. Front brake fluid reservoir 6. On-Command drive switch “2WD/4WD” 7. Throttle lever 8. Front brake lever 9. Main switch...

  • Page 21: Instrument And Control Functions

    EBU1772A INSTRUMENT AND CONTROL FUNCTIONS “ ” (off) EWB00012 WARNING All electrical systems are off. The key can be re- moved. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU26697 Indicator lights and warning lights EBU29913 Main switch 1.
  • Page 22 If the warning light does not come on initially when and then go off. the key is turned to “ ” (on), or if the warning light remains on, have a Yamaha dealer check the electrical circuit.
  • Page 23 “ ” (on), or if the warning steering use when the ATV is traveling at a slow light remains on, have a Yamaha dealer check the speed), the power assist is reduced to protect electrical circuit.

  • Page 24: Display Unit

    “km/h”, and the odometer and tripmeter units will segments will flash repeatedly. If this occurs, have switch to miles or kilometers accordingly. a Yamaha dealer check the vehicle. To switch the display units: turn the key to “ ” (off), then hold the select button “SEL” pushed and turn the key to “...

  • Page 25: Self-Diagnosis Device

    Multi-function display  The odometer will lock at 99999.  The tripmeter will reset and continue counting after 9999.9 is reached. Service tripmeter The service tripmeter shows the distance traveled since it was reset at the last maintenance. To reset the service tripmeter, push the select but- ton “SEL”...

  • Page 26: Handlebar Switches

    If this occurs, have a Yamaha dealer check the vehicle. ECB01181 NOTICE To prevent engine damage, be sure to consult a Yamaha dealer as soon as possible if this oc- curs. EBU18067 Handlebar switches 1. On-Command drive switch “2WD/4WD”...
  • Page 27  “4WD” (four-wheel drive): power is supplied to EBU34123 Light switch “ /OFF” the front and rear wheels, giving maximum trac- Set this switch to “ ” to turn on the left and right tion. headlights (low beams) and the taillight. Set the EWB00164 switch to “...

  • Page 28: Throttle Lever

    EBU18285 EBU18325 Throttle lever Speed limiter 1. Throttle lever 1. Locknut 2. Adjusting screw Push the throttle lever to increase engine speed. 3. No more than 12 mm (0.47 in) Spring tension returns the lever to the rest position The speed limiter keeps the throttle from fully when released.

  • Page 29: Front Brake Lever

    the adjusting screw in direction (b). Do not The front brake lever is located on the right han- turn the adjusting screw out more than 12 dlebar. To apply the front brake, pull the brake le- mm (0.47 in) or the throttle cable could be ver toward the handlebar grip.

  • Page 30: Drive Select Lever

    EBU18614 Drive select lever 1. Rear brake lever The brake pedal is located on the right side of the 1. Drive select lever ATV and the rear brake lever is located on the left The drive select lever is used to shift the transmis- handlebar.

  • Page 31: Fuel Tank Cap

    of sparks, open flames, or other sources of EBU37980 Fuel tank cap ignition such as the pilot lights of water heat- ers and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole.

  • Page 32: Fuel

    3. Wipe up any spilled fuel immediately. Recommended fuel: NOTICE: Immediately wipe off spilled fuel Regular unleaded gasoline (Gasohol [E10] with a clean, dry, soft cloth, since fuel may acceptable) deteriorate painted surfaces or plastic Fuel tank capacity: parts. [ECB00982] 14 L (3.7 US gal, 3.1 Imp.gal) 4.

  • Page 33: Seat

    To install the seat ECB00071 NOTICE 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. EBU34141 Seat To remove the seat 1.

  • Page 34: Storage Compartment

    EBU37061 Storage compartment ECB00131 NOTICE Do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartment. The storage compartment is located under the seat.

  • Page 35: Rear Carrier

    Uneven adjustment can cause poor handling A special wrench can be obtained at a Yamaha and loss of stability, which could lead to an ac- dealer to make this adjustment.

  • Page 36: Trailer Hitch (Yfm45Kpxk / Yfm45Kplk / Yfm45Kphk)

    Maximum (hard): EBU28972 Trailer hitch (YFM45KPXK / YFM45KPLK / YFM45KPHK) This ATV is equipped with a 5 cm (2 in) trailer hitch receiver. Trailer towing equipment can be obtained at a Yamaha dealer. (See page 6-6 for precaution in- formation.) 4-16...

  • Page 37: Auxiliary Dc Jack

    EBU19185 Auxiliary DC jack 1. Trailer hitch receiver 1. Auxiliary DC jack cap 2. Auxiliary DC jack Auxiliary DC jack maximum capacity: 10 A (120 W) A 12-V accessory, such as a work light or radio with the proper adapter, can be used when the en- gine is running and the headlights are turned off.

  • Page 38: Winch Pre-Wiring

     Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged. EBU37290 Winch pre-wiring This vehicle is equipped with pre-wiring leads for a winch. Consult your Yamaha dealer for details. 4-18...

  • Page 39: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 40 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-39, 8-39, 8-41 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.

  • Page 41: Fuel

    Add oil as necessary. (See page 8-19.)  Check that there is no free play in the front EBU19591 brake lever. If there is free play, have a Yamaha Final gear oil dealer check the brake system. Make sure that the final gear oil is at the specified ...

  • Page 42: Throttle Lever

    If there is any leakage, the brake system should be checked by a Yamaha dealer. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly.
  • Page 43 Tire information go, and trailer tongue weight. This ATV is equipped with tubeless tires and tire air valves. After extensive tests, only the tires list- ed below are approved for this model by Yamaha.

  • Page 44: Chassis Fasteners

    Aftermarket tires and rims EWB02552 WARNING The tires and rims that came with your ATV were designed to match the performance capabilities Use of improper tires on this ATV may cause and to provide the best combination of handling, loss of control, increasing your risk of an acci- dent.

  • Page 45: Operation

    See the “Engine break-in” section on page 6-4 the ATV. If there is a control or function you do not prior to operating the engine for the first time. understand, ask your Yamaha dealer. EWB00632 WARNING To start the engine 1.

  • Page 46: Operating The Drive Select Lever And Driving In Reverse

    ECB03330 on. If the indicator light does not come on, NOTICE have a Yamaha dealer check the electrical Do not shift without coming to a complete stop circuit. and waiting for the engine to return to normal 3.
  • Page 47 reverse, make sure there are no people or ob- stacles behind you. When it is safe to proceed, go slowly. 1. Bring the ATV to a complete stop. 2. Apply the brake pedal. 3. Shift from neutral to reverse or from reverse to park and vice versa by moving the drive se- lect lever along the shift guide.

  • Page 48: Engine Break-In

    Vary the speed of the ATV regularly. Do not oper- should come on. If the indicator light does not ate it at one set throttle position. come on, have a Yamaha dealer check the elec- trical circuit. 120–240 km (75–150 mi) or 10–20 hours ...

  • Page 49: Parking On A Slope

    Yamaha for use on your ATV. Many companies with no connection to Yamaha manufacture parts and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket compa- nies produce. Therefore, Yamaha can neither en-...
  • Page 50 Yamaha or modifications not specifically bulky object attached to the handlebars which recommended by Yamaha, even if sold and in- could make steering difficult, an accessory that stalled by a Yamaha dealer. limits your ability to move around on the seat, or one that limits your view.
  • Page 51  Never exceed the weight limits shown. An over- the weight on the hitch. If you are carrying cargo loaded ATV can be unstable. and towing a trailer, include the tongue weight in the maximum ATV load limit.  Load cargo on the carriers as close to the center MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, car- of the ATV as possible.
  • Page 52 EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 53: Riding Your Atv

    EBU21133 RIDING YOUR ATV...

  • Page 54: Getting To Know Your Atv

    Before you begin to ride, be complete the certified training course offered by sure you have read this Owner’s Manual com- Yamaha. They should then regularly practice the pletely and understand the operation of the con- skills learned in the course and the operating tech-...
  • Page 55 more information about the training course, con- tact an authorized ATV dealer or call 1-800-887- 2887. Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics.
  • Page 56 This ATV is designed to carry the operator and cargo only – passengers prohibited. The long seat is to allow the operator to shift posi- tion as needed during operation. It is not for carry- ing passengers. WARNING! Never carry a passenger.
  • Page 57 Apparel Always wear the following to reduce risk of injury in an accident:  Approved motorcycle helmet that fits properly  Eye protection (goggles, helmet face shield, or protective eyewear)  Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 58 Do not operate after or while consuming alco- nance procedures and schedules described in the hol or drugs. Owner’s Manual. WARNING! Failure to inspect The operator’s performance capability is reduced the ATV before riding it or failure to maintain it by the influence of alcohol or drugs.
  • Page 59  Make sure the load does not interfere with your control or ability to see where you are going.  Tie down cargo in the trailer securely. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. ...
  • Page 60 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during ATV loading limit (total weight of cargo, rid- operation; otherwise, they may contact the rear er, accessories, and tongue): wheels. WARNING! Removing even one hand or 240.0 kg (530 lb) foot can reduce your ability to control the ATV Front carrier: or could cause you to lose your balance and...
  • Page 61 ATV should during operation or after leaving the ATV, do not be genuine Yamaha or equivalent components let brush, grass and other materials collect under designed for use on this ATV and should be in- the vehicle, near the muffler or exhaust pipe, or stalled and used according to instructions.

  • Page 62: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for off-road use only. children are not likely to touch it. WARNING! Paved surfaces may seriously af- fect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 63 WARNING! Never operate this ATV on any pu- blic street, road or highway, even a dirt or grav- el one. You could collide with another vehicle. [EWB01032] Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset.
  • Page 64 Do not operate on rough, slippery, or loose terrain with another vehicle if operating in off-road ar- until you have learned and practiced the skills nec- eas where you cannot easily be seen. Mount a essary to control the ATV on such terrain. Always caution flag on the ATV to make you more vis- be especially cautious on these kinds of terrain.

  • Page 65: Turning Your Atv

    resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. Improper use of the brakes can cause the tires to lose traction, reducing control and increasing the possibility of an accident.
  • Page 66 To achieve maximum traction while riding off- road, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turn- ing technique must be used to allow the ATV to make turns quickly and easily.

  • Page 67: Climbing Uphill

     Never go over the top of any hill at high Improper riding procedures such as abrupt throt- tle changes, excessive braking, incorrect body speed. An obstacle, a sharp drop, or another movements, or too much speed for the sharpness vehicle or person could be on the other side of the turn may cause the ATV to tip.
  • Page 68 Do not attempt to climb hills until you have mas- tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
  • Page 69 If you are climbing a hill and you find that you have around and remount, following the procedure de- not properly judged your ability to make it to the scribed in the Owner’s Manual. WARNING! Stall- top, you should turn the ATV around while you still ing, rolling backwards...

  • Page 70: Riding Downhill

    RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- EWB01622 WARNING sible. Move back on the seat and sit with your arms straight. Engine compression will do most of Going down a hill improperly could cause over- turns or loss of control.

  • Page 71: Crossing A Slope

     Always follow proper procedures as de- Whenever possible, ride your ATV straight down- hill. Avoid sharp angles which could allow the ATV scribed in the Owner’s Manual.  Avoid hills with excessively slippery or loose to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- surfaces.

  • Page 72: Crossing Through Shallow Water

    If your ATV does begin to tip over, gradually steer than the depth specified in your Owner’s Man- in the downhill direction if there are no obstacles ual, as tires may float, increasing the risk of an in your path. As you regain proper balance, grad- overturn.
  • Page 73 without verifying that you have regained proper braking ability. WARNING! Wet brakes may have reduced stopping ability, which could cause loss of control. [EWB02622] 1. Air filter case check hose After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case and the V-belt cooling duct check hose.

  • Page 74: Riding Over Rough Terrain

    accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01663 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 75: What To Do If

    To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting If the rear wheels of your ATV start to slide side- such maneuvers, since both stability and control...

  • Page 76: What To Do

     If your ATV is traversing a sloping surface: WHAT TO DO...  If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.

  • Page 77: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 78: Owner's Manual And Tool Kit

    If you do not have the tools or experience required Be sure to put the Owner’s Manual and the low- for a particular job, have a Yamaha dealer perform pressure tire gauge in the plastic bag and always it for you.

  • Page 79: Periodic Maintenance Chart: Emission Control System

     For odometer or hour meter-equipped vehicles, follow the month maintenance interval if the ATV isn’t ridden for the stated distance or engine operating hours.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 80 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours √ √ √ Spark arrester • Clean. • Check the air cut-off valve, reed valve, and hose Air induction sys- for damage.

  • Page 81: Periodic Maintenance Chart: General Maintenance And Lubrication

     For odometer or hour meter-equipped vehicles, follow the month maintenance interval if the ATV isn’t ridden for the stated distance or engine operating hours.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 82 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. √ √ √ √ √ • Check brake lever and pedal free play, and adjust if necessary.
  • Page 83 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Make sure that all nuts, bolts, and screws are √ √ √ √ √ Chassis fasteners properly tightened.
  • Page 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Change. √ √ Differential gear oil • Check ATV for oil leakage, and correct if neces- sary.
  • Page 85 EBU28392  Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle.  Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinder and calipers, and chan- ge the brake fluid.

  • Page 86: Removing And Installing Panels

    EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU23091 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed.
  • Page 87 EBU27605 Panel A When removing or installing panel A, the fuel tank cap must be removed. NOTICE: Make sure that no foreign material enters the fuel tank. [ECB01052] To remove the panel 1. Remove the seat. (See page 4-13.) 2. Remove the bolts and quick fasteners. 1.
  • Page 88 4. Install the fuel tank cap. To remove a panel 1. Remove panel A. To install the panel 2. Pull the panel upward to release the tabs as 1. Remove the fuel tank cap. shown. 2. Place the panel over the fuel tank filler tube, and then install the fuel tank cap.
  • Page 89 To install a panel Panel D 1. Push the panel to secure the tabs. To remove the panel Remove the bolts, and then take the panel off. 1. Bolt 2. Panel D To install the panel Place the panel in the original position, and then install the bolts.
  • Page 90 YFM45KPXK / YFM45KPLK / YFM45KPHK: Remove the handlebar- mounted light cover. (See page 8-58.)  For YFM45KDXK / YFM45KDHK: Remove the handlebar cover. YFM45KPXK / YFM45KPLK / YFM45KPHK To install the panel Insert the right side of the panel into position, and then press the projections into place.
  • Page 91 YFM45KDXK / YFM45KDHK 1. Carrier bolt (top) 1. Handlebar cover 2. Panel F 3. Remove the carrier top bolts. 4. Remove the carrier bolts under the fenders, and then take the carrier off. 8-15...
  • Page 92 1. Carrier bolt (under the fenders) 1. Quick fastener 6. Lift up the panel and disconnect the coupler. 1. Carrier bolt (under the fenders) 1. Coupler 5. Remove the quick fasteners. 8-16...

  • Page 93: Checking The Spark Plug

    YFM45KPXK / YFM45KPLK / el in the original position. YFM45KPHK: Install the handlebar-mount- ed light cover.  For YFM45KDXK / YFM45KDHK: Install the handlebar cover. 6. Install the panels. EBU23215 Checking the spark plug The spark plug is an important engine component, which is easy to check.
  • Page 94 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. 1. Spark plug cap 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and 2.

  • Page 95: Engine Oil And Oil Filter Cartridge

    Tightening torque: Spark plug: 18 N·m (1.8 kgf·m, 13 lb·ft) If a torque wrench is not available when installing the 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 speci- fied torque as soon as possible.
  • Page 96 If the engine was started before checking the oil The engine oil should be between the tip of the level, warm up the engine, and then wait at least dipstick and the maximum level mark. ten minutes until the oil settles for an accurate reading.
  • Page 97 7. Check the filler cap O-ring for damage, and replace it if necessary. 8. Install the engine oil filler cap and the panel. To change the engine oil (and replace the oil fil- ter cartridge) 1. Park the ATV on a level surface. 2.
  • Page 98 An oil filter wrench is available at a nearby Yamaha dealer. 8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 1. Oil filter cartridge 1. O-ring Make sure that the O-ring is properly seated.
  • Page 99 12. Refill with the specified amount of the recom- mended engine oil. 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 100: Final Gear Oil

    If any leakage is found, have 4. Correct oil level a Yamaha dealer check and repair the ATV. In ad- 3. If the oil is below the brim of the filler hole, add dition, the final gear oil level must be checked and...
  • Page 101 To change the final gear oil 1. Park the ATV on a level surface. 2. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil drain bolt 2. Gasket 5. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque.
  • Page 102 10. Install the final gear case guard by installing the bolts, and then tightening them to the Recommended final gear oil: specified torque. Yamaha Friction Modified Shaft Drive Gear Tightening torque: Oil quantity: Final gear case guard bolt: 0.38 L (0.40 US qt, 0.33 Imp.qt) 8 N·m (0.8 kgf·m, 5.9 lb·ft)

  • Page 103: Changing The Differential Gear Oil

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 104: Coolant

    6. Check the oil filler bolt gasket for damage, and replace it if necessary. 7. Install the oil filler bolt and its gasket, and then If genuine Yamaha coolant is not available, use an tighten the bolt to the specified torque. ethylene glycol antifreeze containing corrosion in-...
  • Page 105 ECB02190 NOTICE Mix antifreeze with distilled water only. Howev- er, if distilled water is not available, soft water may be used for refilling. Do not use hard water or salt water since they are harmful to the en- gine. EBU2712A To check the coolant level 1.
  • Page 106 WARNING! Remove only the coolant res- water has been added to the coolant, have ervoir cap. Never attempt to remove the a Yamaha dealer check the antifreeze con- radiator cap when the engine is hot. tent of the coolant as soon as possible,...
  • Page 107 1. Radiator cap 1. Coolant drain bolt 2. Gasket 4. Remove panels D and E. (See page 8-10.) 3. Trough 5. Place a container under the engine, and then 6. Remove the coolant reservoir cap. remove the coolant drain bolt and its gasket. 7.

  • Page 108: Cleaning The Air Filter

    12. Pour the recommended coolant into the radi- ator until it is full, and then install the radiator cap. 13. Start the engine, let it idle for several minutes, and then turn it off. While the engine is idling, check the cooling sys- tem for leaks.
  • Page 109  Replace the air filter elements if damaged.  Service the air filter more frequently if you often ride in wet or dusty areas.  There is a check hose at the bottom of the air fil- ter case. If dust or water collects in this hose, empty the hose and clean the air filter case and air filter elements.
  • Page 110 5. Pull off the lock plate from the main air filter assembly, and then remove the air filter ele- ment (sponge material) from the frame. 1. Main air filter assembly 1. Frame 2. Air filter element (sponge material) 3. Lock plate 6.

  • Page 111: Cleaning The Spark Arrester

    7. Squeeze out the excess moisture, and let dry. 12. Install the air filter case cover by hooking the NOTICE: Do not twist the sponge material holders onto the cover. NOTICE: Make sure when squeezing it. that the air filter element is properly seated [ECB00442] in the air filter case.

  • Page 112: V-Belt Cooling Duct Check Hose

    3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Check the gasket for damage. Replace if nec- essary. 5.

  • Page 113: V-Belt Case Drain Plug

    V-belt case, remove the V-belt case drain plug to drain the water from the case. If water drains from the V-belt case after removing the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts. 8-37...

  • Page 114: Adjusting The Throttle Lever Free Play

    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 periodic maintenance and lu- 1. Throttle lever free play brication chart.

  • Page 115: Checking The Front Brake Pads And Rear Brake Friction Plates

    EBU30321 Front brake pads Rear brake friction plates The rear brake friction plates must be checked and, if necessary, replaced by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. EBU29844 Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark.
  • Page 116 Therefore, be sure to check the brake pads for wear and the brake system for leakage. If the brake fluid level suddenly goes down, have a Yamaha dealer the brake system before further riding. EWB02721 WARNING Improper maintenance can result in loss of braking ability.

  • Page 117: Changing The Brake Fluid

     Brake hoses: Replace every four years. 1. No brake lever free play There should be no free play at the brake lever end. If there is free play, have a Yamaha dealer in- spect the brake system. EBU30348 Adjusting the rear brake lever and...
  • Page 118 Adjusting the brake lever free play 1. Locknut 2. Distance A 1. Brake lever free play 3. Brake lever free play adjusting bolt Brake lever free play: 2. To increase the brake lever free play, turn the 10.0 mm (0.39 in) brake lever free play adjusting bolt in direction (a).
  • Page 119 22 mm (0.87 in), adjust the brake lever free play at the brake lever again. If distance A 3. Fully turn the adjusting bolt in direction (a) to exceeds 12.7 mm (0.50 in), have a Yamaha loosen the brake cable. dealer check the vehicle.
  • Page 120 Brake pedal height: 80.0 mm (3.15 in) Measure the brake pedal height and adjust if nec- essary. 1. Remove the footboard by removing the quick fasteners, bolts, and nuts. 1. Locknut 2. Adjusting bolt 3. Turn the adjusting bolt in or out until the brake pedal height is within the specified limits.
  • Page 121 1. Footboard bolt A Tightening torques: 2. Footboard bolt B Footboard bolt A: 3. Quick fastener 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Footboard bolt B: 8 N·m (0.8 kgf·m, 5.9 lb·ft) Tighten the footboard bolts in the order shown. 8-45...

  • Page 122: Axle Boots

    Check the axle boots for 1. Loosen the locknut. tears or damage. If any damage is found, have them replaced by a Yamaha dealer. 8-46...

  • Page 123: Brake Light Switches

    The rear 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. Turn the rear brake light switch adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a).

  • Page 124: Checking And Lubricating The Cables

    EBU28712 essary. If a cable is damaged or does not move Checking and lubricating the front and smoothly, have a Yamaha dealer check or replace rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever Recommended lubricant: pivots should be lubricated if necessary.

  • Page 125: Checking And Lubricating The Brake Pedal

    Front brake lever EBU28872 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease Rear brake lever EBU24964 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 126: Lubricating The Drive Shaft Universal Joint

    Yamaha dealer check the wheel hub bearings. 1. Grease nipple For parts equipped with a grease nipple, use a EBU24974 Lubricating the drive shaft universal grease gun.

  • Page 127: Lubricating The Rear Knuckle Pivots

    EBU25095 Recommended lubricant: Lubricating the steering shaft Lithium-soap-based grease The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 8-51...

  • Page 128: Battery

    YFM45KDXK / YFM45KDHK For parts equipped with a grease nipple, use a grease gun. EBU2918B Battery This model is equipped with a 12-volt VRLA (valve-regulated lead-acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and tightened, and the bat- tery terminals cleaned if corroded.
  • Page 129 EWB02161 WARNING Battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can cau- se severe burns. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk.
  • Page 130 ECB00622 ECB00942 NOTICE NOTICE  Always keep the battery charged. Storing the Never attempt to open the battery or remove the battery cell seals, as this would permanent- battery in a discharged state for an extended ly damage the battery. period of time will cause permanent battery damage.

  • Page 131: Replacing A Fuse

    EBU30805 Replacing a fuse For non-EPS models 1. Positive battery lead (red) 2. Negative battery lead (black) 3. Install the battery holding plate by installing 1. Fuel injection system spare fuse the bolts. 2. Fuel injection system fuse 4. Install the seat. (See page 4-13.) 3.
  • Page 132 For EPS models 3 4 5 1. Auxiliary DC jack fuse 1. Fuel injection system spare fuse 2. Four-wheel-drive motor fuse 2. Fuel injection system fuse 3. Ignition fuse 3. Main fuse 4. Radiator fan motor fuse 4. EPS fuse 5.
  • Page 133 2. Remove the seat. (See page 4-13.) 3. Remove the blown fuse, and then install a 3 4 5 new fuse of the specified amperage. WARNING! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in place of the proper fuse.

  • Page 134: Replacing A Headlight Bulb

    2. Remove the bulb cover by pulling it off. 4. Turn on the main switch, start the engine, and then turn on the circuit in question. 5. If the fuse immediately blows again, have a Yamaha dealer check the vehicle. 8-58...
  • Page 135 4. Remove the burnt-out bulb. 5. Place a new bulb into position. NOTICE: Do not touch the glass part of the bulb. Oil from your fingers or other contamination will adversely affect the transparency of the glass, luminosity of the bulb, and bulb life.
  • Page 136 7. Install the bulb cover and the cover at the rear of the headlight. NOTICE: Make sure the bulb cover is securely fitted over the sock- et and seated properly. [ECB03320] 8. Adjust the headlight beam if necessary. Handlebar-mounted light bulb (YFM45KPXK / YFM45KPLK / YFM45KPHK) 1.

  • Page 137: Adjusting A Headlight Beam

    Adjusting a headlight beam ECB00691 NOTICE 1. Do not touch the glass part of the bulb. It is advisable to have a Yamaha dealer make this adjustment. 6. Install the socket by pushing it in and turning it clockwise. To raise a headlight beam, turn the headlight 7.

  • Page 138: Replacing The Brake/Tail Light Bulb

    EBU25615 Replacing the brake/tail light bulb If the brake/tail light bulb burns out, replace it as follows. 1. Remove the brake/tail light bulb holder (to- gether with the bulb) by turning it counter- clockwise. 1. Headlight beam adjusting screw YFM45KPXK / YFM45KPLK / YFM45KPHK 1.

  • Page 139: Removing A Wheel

    1. Brake/tail light bulb 1. Wheel nut 3. Insert a new bulb into the bulb holder, push it 3. Elevate the ATV and place a suitable stand in, and then turn it clockwise until it stops. under the frame. 4. Install the bulb holder (together with the bulb) 4.
  • Page 140 2. Lower the ATV to the ground. 3. Wheel nut 3. Tighten the wheel nuts to the specified torques. For YFM45KDXK / YFM45KDHK / YFM45KPXK / Tightening torques: YFM45KPHK: be sure to install the nuts with their Front wheel nut: tapered side towards the wheel.

  • Page 141: Troubleshooting

    The following troubleshooting charts represent quick and easy procedures for checking these vi- tal systems yourself. However, should your ATV require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the ATV properly.

  • Page 142: Troubleshooting Charts

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the compression. 4. Compression The engine does not start. There is compression.
  • Page 143 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK.  Tap water can be used in an emergency. Change to the recommended coolant as soon as possible.

  • Page 144: Cleaning And Storage

    EBU25861 CLEANING AND STORAGE and deterioration of wheel bearings, EBU25882 Cleaning brakes, transmission seals and electrical Frequent, thorough cleaning of your ATV will not devices. Many expensive repair bills have only enhance its appearance but will improve its resulted from improper high-pressure de- general performance and extend the useful life of tergent applications such as those avail- many components.

  • Page 145: Storage

    4. Perform the following steps to protect the en- EBU27264 Storage gine from internal corrosion. a. Remove the spark plug cap and spark Short-term plug. Always store your ATV in a cool, dry place and, if b. Pour a teaspoonful of engine oil into the necessary, protect it against dust with a porous spark plug bore.
  • Page 146 8. Remove the battery and fully charge it. (See page 8-52.)

  • Page 147: Specifications

    35 cm (14 in) Electric starter Weight: Lubrication system: Wet sump Curb weight: Engine oil: 289.0 kg (637 lb) (YFM45KDHK, YFM45KDXK) 295.0 kg (650 lb) (YFM45KPHK, YFM45KPLK, Recommended brand: YFM45KPXK) YAMALUBE Loading: SAE viscosity grades: 5W-30, 10W-30, 10W-40, 15W-40, 20W-40, 20W-50 Maximum loading limit: 240.0 kg (530 lb)
  • Page 148 0.38 L (0.40 US qt, 0.33 Imp.qt) Spark plug gap: Differential gear oil: 0.6–0.7 mm (0.024–0.028 in) Type: Drivetrain: Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 Primary reduction ratio: API GL-4 Hypoid gear oil 1.000 Quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt)
  • Page 149 Secondary reduction ratio: Recommended: 7.944 (39/24 x 24/18 x 33/9) Front: Final drive: 35.0 kPa (0.350 kgf/cm², 5.0 psi) Shaft Rear: Clutch type: 30.0 kPa (0.300 kgf/cm², 4.4 psi) Wet, centrifugal, shoe Minimum: Transmission type: Front: CVT automatic with reverse 32.0 kPa (0.320 kgf/cm², 4.6 psi) Gear ratio: Rear:...
  • Page 150 Shock absorber: Brake/tail light: Gas-hydraulic damper 21.0 W/5.0 W Wheel travel: Meter lighting: 171 mm (6.8 in) Rear suspension: Neutral indicator light: Type: Reverse indicator light: Double wishbone Spring: Coolant temperature warning light: Coil spring Shock absorber: Parking brake indicator light: Gas-hydraulic damper Wheel travel: Four-wheel-drive indicator light:...
  • Page 151 Four-wheel-drive motor fuse: 3.0 A Radiator fan motor fuse: 20.0 A EPS fuse: 40.0 A (YFM45KPHK, YFM45KPLK, YFM45KPXK) 10-5...

  • Page 152: Consumer Information

    Yamaha dealer or for reference in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 153 Model label ment Canada. 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 dealer. 11-2...
  • Page 154 1. Vehicle Emission Control Information label 11-3...

  • Page 155: Noise Regulation

    EBU26061 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 156: Maintenance Record

    EBU36900 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work. MAINTENANCE INTERVAL DATE OF SERVICING DEALER...

  • Page 157: Yamaha Motor Corporation, U.s.a. 2015 And Later Model Atv Limited Warranty

    EBU30971 YAMAHA MOTOR CORPORATION, U.S.A. 2015 AND LATER MODEL ATV LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants SPECIFIC EXCLUSIONS from this warranty shall warranty to remain in effect, this inspection and that new Yamaha ATVs purchased from include parts replaced due to normal wear or routine...
  • Page 158 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 159: Yamaha Extended Service (Y.e.s.)

    Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to “moving par ts” or the “drive train” like many other plans.
  • Page 160 Yamaha. See your dealer today! YAMAHA EXTENDED SERVICE A special note: If visiting your dealer isn’t convenient, contact Yamaha with your VIN number (vehicle identification number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O. Box 6555...

  • Page 161: Index

    INDEX Differential gear oil, changing ........8-27 Display unit ..............4-4 Accessories and loading ..........6-5 Drive select lever ............4-10 Accessories, DC jack ........... 4-17 Drive select lever and driving in reverse ......6-2 Air filter, cleaning ............8-32 Drive shaft universal joint, lubricating ......
  • Page 162 Spark arrester, cleaning ..........8-35 Spark plug, checking ........... 8-17 Label locations ...............1-1 Specifications .............. 10-1 Light switch ..............4-7 Speed limiter ..............4-8 Stabilizer bushes, checking ......... 8-50 Main switch ..............4-1 Starting the engine ............6-1 Maintenance and lubrication chart ........8-5 Start switch ..............
  • Page 163 EBU30393 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect.
  • Page 164 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER ALWAYS operate: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough...

This manual is also suitable for:

Kodiak 450Yfm45kdhkYfm45kpxkYfm45kplkYfm45kphk

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