Yamaha YFZ450R 2017 Owner's Manual
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Yamaha YFZ450R 2017 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
OWNER'S MANUAL
YFZ45YSXJ
YFZ45YSSJ
BW2-F8199-61

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  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFZ45YSXJ YFZ45YSSJ BW2-F8199-61...
  • Page 2 Original instructions Notice originale Manual original PRINTED IN USA 2017.06-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFZ45YSXJ YFZ45YSSJ WARNING This ATV should not be ridden by anyone under 16 years of age. BW2-F8199-61-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFZ450R (YFZ45YSX)
  • Page 5 Congratulations on your purchase of the Yamaha YFZ45YSXJ / YFZ45YSSJ. This ATV represents the re- sult of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 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 7 Please check your local riding laws and regulations before operating this ATV. EBU17411 YFZ45YSXJ / YFZ45YSSJ OWNER’S MANUAL ©2017 by Yamaha Motor Co., Ltd. 1st edition, April 2017 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 8: Table Of Contents

    EBU17421 TABLE OF CONTENTS LOCATION OF THE WARNING AND Seat ............4-10 SPECIFICATION LABELS ......1-1 Front shock absorbers ......4-11 Rear shock absorbers ......4-16 SAFETY INFORMATION ........2-1 Handlebar position ........4-23 DESCRIPTION..........3-1 PRE-OPERATION CHECKS ......5-1 Left view............3-1 Fuel ............. 5-4 Right view............3-1 Engine oil ............
  • Page 9 RIDING YOUR ATV ........7-1 Coolant ............. 8-20 GETTING TO KNOW YOUR ATV ....7-2 Cleaning the air filter element ....8-21 RIDE WITH CARE AND GOOD Cleaning the spark arrester ...... 8-25 JUDGMENT ..........7-2 Adjusting the throttle lever free play..8-27 BE CAREFUL WHERE YOU RIDE....
  • Page 10 Battery............8-42 Replacing the fuse ........8-45 Replacing a headlight bulb .......8-46 Adjusting a headlight beam ......8-48 Tail/brake light...........8-49 Removing a wheel........8-49 Installing a wheel........8-49 Troubleshooting ........8-50 Troubleshooting charts ......8-51 CLEANING AND STORAGE ......9-1 Cleaning ............9-1 Storage............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION .......11-1 Identification numbers ......11-1 INDEX............12-1...

  • Page 11: Location Of The Warning And Specification Labels

    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.
  • Page 12 YAMAHA 1HP-F811R-00 YAMAHA 1P0-F816R-00...
  • Page 13 35.0 kPa 0.35 kgf/cm² 0.35 kgf/cm² 5.0 psi 5.0 psi YAMAHA 3C2-F816P-00 1TD-F816M-M0 Use PREMIUM unleaded gasoline with min. 97 octane (RON). Nur Super Bleifrei mit Mindestoktanzahl 97 (ROZ) tanken. Utilice gasolina sin plomo que tenga como mínimo 97 octanos(RON).
  • Page 14 YAMAHA MOTOR CO., LTD. SHIZUOKA JAPAN YAMAHA 4GB-2155A-00 1HP-F2259-21...
  • Page 15 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
  • Page 16 This pictogram shows the loading limits EN228 fuel identification mark. Gasoline of ethanol 10% or less can be and/or maximum load capacity for this ATV. Follow all load limits and other loading used. guidelines in this manual. Load may include the driver, passenger, human protective gear, accessories, goods, luggage, and all other load related items.

  • Page 17: Safety Information

    EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Never allow a child under age 16 to operate an EBU29374 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 18  Never operate at speeds too fast for your skills  Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 19  Never operate an ATV in fast flowing water or in technique described in this manual on level ground. Avoid crossing the side of a steep hill if water deeper than that recommended in this possible. manual. Remember that wet brakes may have ...
  • Page 20 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 21 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 22  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, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nau- sea, confusion, and eventually death.

  • Page 23: Description

    EBU17681 DESCRIPTION EBU17691 EBU17701 Left view Right view 1. Front shock absorber 1. Spark arrester 2. Engine oil tank filler cap 2. Fuse 3. Rear brake fluid reservoir 3. Fuel tank cap 4. Battery 4. Oil filter element 5. Shift pedal 5.

  • Page 24: Controls And Instruments

    EBU17715 Controls and instruments 1. Clutch lever 2. Parking brake lever 3. Handlebar switches 4. Main switch 5. Front brake fluid reservoir 6. Throttle lever 7. Brake lever...

  • Page 25: Instrument And Control Functions

    EBU17739 INSTRUMENT AND CONTROL FUNCTIONS EBU29913 EBU29383 Main switch Indicator light and warning lights 1. Main switch 1. Fuel level warning light “ ” 2. Engine trouble warning light “ ” “ ” (on) 3. Coolant temperature warning light “ ”...
  • Page 26 “ ” (on), or if the warning If the warning light does not come on initially when light remains on, have a Yamaha dealer check the the key is turned to “ ” (on), or if the warning vehicle.

  • Page 27: Handlebar Switches

    “ ” (on), or if the warning tion. The engine will not start or run when this light remains on, have a Yamaha dealer check the switch is set to “ ”. electrical circuit.

  • Page 28: Throttle Lever

    EBU18284 EBU18325 Throttle lever Speed limiter 1. Locknut 1. Throttle lever 2. Adjusting screw Push the throttle lever to increase engine speed 3. No more than 12 mm (0.47 in) and the speed of the ATV. Because the throttle is The speed limiter keeps the throttle from fully spring-loaded, the ATV will decelerate and the en- opening, even when the throttle lever is pushed to...

  • Page 29: Clutch Lever

    the adjusting screw in direction (b). Do not The clutch lever is located on the left side of the turn the adjusting screw out more than 12 handlebar. To disengage the clutch, pull the clutch mm (0.47 in) or the throttle cable could be lever toward the handlebar grip.

  • Page 30: Brake Pedal

    The brake lever is located on the right handlebar. The brake pedal is located on the right side of the To apply the front brake, pull the brake lever to- ATV. To apply the rear brake, push down on the ward the handlebar grip.

  • Page 31: Shift Pedal

    braking performance which could cause an accident. You could also wear out the brakes prematurely. EBU18532 Shift pedal 1. Parking brake lever (unlocked position) EWB00221 WARNING  Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- 1.

  • Page 32: Fuel Tank Cap

    EBU18722 EWB02522 Fuel tank cap WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, fol- low these instructions. 1. Before refueling, turn off the engine and be sure that no one is sitting on the vehicle.
  • Page 33 1. Maximum fuel level 1. EN228 fuel identification mark 2. Fuel tank filler tube Recommended fuel: When refueling, check that the gasoline pump Premium unleaded gasoline, octane 97 or nozzle has the same identification mark. higher Fuel tank capacity: ECB00071 NOTICE 10.0 L (2.64 US gal, 2.20 Imp.gal) Fuel reserve amount:...

  • Page 34: Seat

    3. After refueling, return the nozzle and then EBU26733 Seat close the fuel tank cap fully by turning it clockwise. Make sure the fuel tank cap is se- To remove the seat curely closed. 4. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic...

  • Page 35: Front Shock Absorbers

    To install the seat pression damping), and a compression damping force adjusting screw (for slow compression damping). EWB02492 WARNING  Suspension components become hot during operation. Never touch the compression damping force adjusting bolt and screw, the rebound damping force adjusting screw or the oil reservoir with your bare hand or skin until suspension components have cooled.
  • Page 36 3. Special wrench tion (b) to decrease the spring preload and thereby soften the suspension.  A special wrench can be obtained at a Yamaha dealer to make this adjustment.  The spring preload setting is determined by measuring distance A, shown in the illustration.
  • Page 37 Spring preload setting: Tightening torque: Minimum (soft): Locknut: Distance A = 302.5 mm (11.91 in) 50 N·m (5.0 kgf·m, 37 lb·ft) Standard: Distance A = 293.0 mm (11.54 in) Rebound damping force Maximum (hard): Turn the rebound damping force adjusting screw Distance A = 282.5 mm (11.12 in) in direction (a) to increase the rebound damping force and thereby harden the damping, and in di-...
  • Page 38 Rebound damping setting: Minimum (soft): 30 click(s) in direction (b)* Standard: 16 click(s) in direction (b)* Maximum (hard): 1 click(s) in direction (b)* * With the adjusting screw fully turned in di- rection (a) Compression damping force 1. Fast compression damping force adjusting bolt Fast compression damping force Fast compression damping setting: To increase the fast compression damping force...
  • Page 39 Slow compression damping force Slow compression damping setting: To increase the slow compression damping force Minimum (soft): and thereby harden the compression damping, 20 click(s) in direction (b)* turn the slow compression damping force adjust- Standard: ing screw in direction (a). To decrease the slow 7 click(s) in direction (b)* compression damping force and thereby soften Maximum (hard):...

  • Page 40: Rear Shock Absorbers

     Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the Although the total number of clicks or turns of a shock absorber assembly to a Yamaha deal- damping force adjusting mechanism may not ex- er for any service.
  • Page 41 1. Hose holder 1. Clamp screw 2. Clip 4. Remove the air filter case holding plate by re- 3. Bolt moving the bolts and collars. 4. Blow-by gas chamber 3. Loosen the clamp screw at the air filter case side. 4-17...
  • Page 42 1. Bolt 1. Air filter case 2. Bolt 2. Collar 3. Air filter case holding plate 6. Disconnect the coupler. 5. Remove the bolts, and then remove the air fil- ter case by disconnecting it from the air in- take duct. 1.
  • Page 43 2. Spring preload adjusting nut 3. Special wrench 1. Clamp screw 2. Air intake duct  A special wrench can be obtained at a Yamaha 8. Loosen the locknut. dealer to make this adjustment. 9. Turn the spring preload adjusting nut in direc- ...
  • Page 44 Spring preload setting: Tightening torque: Minimum (soft): Locknut: Distance A = 286.5 mm (11.28 in) 30 N·m (3.0 kgf·m, 22 lb·ft) Standard: 11. Connect the air intake duct to the throttle Distance A = 278.0 mm (10.94 in) body, and then tighten the clamp screw at the Maximum (hard): throttle body side.
  • Page 45 15. Install the air filter case holding plate by in- stalling the bolts and collars, and then tighten the bolts to the specified torque. Tightening torque: Air filter case holding plate bolt: 7 N·m (0.7 kgf·m, 5.2 lb·ft) 16. Install the blow-by gas chamber by installing the bolt, tighten the bolt to the specified torque, and then install the clip to the hose holder.
  • Page 46 Compression damping force Fast compression damping setting: Remove the seat to make this adjustment. (See Minimum (soft): page 4-10.) If the adjustment is difficult, it may be 2 turn(s) out from the fully turned in posi- necessary to remove panels A and C. (See page tion 8-10.) Standard:...

  • Page 47: Handlebar Position

    * With the adjusting screw fully turned in di- EBU29403 rection (a) Handlebar position The handlebar can be adjusted to one of two po- sitions to suit the rider’s preference. Have a Yamaha dealer adjust the position of the handle- bar. 4-23...
  • Page 48 1. Handlebar 4-24...

  • Page 49: 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 50 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 5-4, 8-28, 8-29, 8-31 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.
  • Page 51 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate lever pivoting points Brake and clutch levers 8-39 if necessary. Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. Instruments, lights and • Check operation, and correct if necessary. switches...

  • Page 52: Fuel

    Yamaha dealer check the brake sys- tem. Brake lever and brake pedal  Check that there is no free play in the brake le- ver. If there is free play, have a Yamaha dealer check the brake system.

  • Page 53: Throttle Lever

    Check the operation of the throttle lever. It must also cause the tire to dislodge from the rim un- open smoothly and spring back to the idle position der severe riding conditions. [EWB02542] when released. Have a Yamaha dealer correct if necessary. Recommended tire pressure: Front EBU19771 35.0 kPa (0.350 kgf/cm², 5.0 psi)
  • Page 54 (See page 8-2.) air valves. After extensive tests, only the tires list- When using the tire pressure gauge, make two ed below are approved for this model by Yamaha. measurements and use the second reading as grit EWB02552...

  • Page 55: Chassis Fasteners

    EBU19851 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are MAXXIS/MS21 working properly. Correct if necessary. Size: AT21 x 7R10 Type: Tubeless Rear: Manufacturer/model: MAXXIS/MS22 Size: AT20 x 10R9 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling,...

  • Page 56: Operation

    3. Shift the transmission into neutral. The neutral vent any loss of control, which could cause an indicator light should come on, if it does not accident or injury. come on, have a Yamaha dealer check the electrical circuit. EBU29954 Starting the engine...

  • Page 57: Shifting

    If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt.
  • Page 58 4. Open the throttle gradually and at the same shifting can cause the tires to lose traction, reduc- time, release the clutch lever slowly. ing control and increasing the possibility of an ac- WARNING! Opening the throttle abruptly cident. or releasing the clutch lever too quickly EWB00712 WARNING could make the ATV wheelie, which would...

  • Page 59: Engine Break-In

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

  • Page 60: Parking On A Slope

    EBU20922 ing brake, and then block the front and rear Genuine Yamaha Accessories wheels with rocks or other objects. Choosing accessories for your ATV is an impor- tant decision. Genuine Yamaha Accessories, which are available only from a Yamaha dealer,...
  • Page 61  Accessories should be rigidly and securely and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to mounted. An accessory which can shift position test the products that these aftermarket compa- or come off while you are riding could affect nies produce.
  • Page 62  Tie down cargo securely to the carriers. Make curely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater dis- sure cargo in the trailer cannot move around. A tance for braking. shifting load can cause an accident. ...

  • Page 63: Riding Your Atv

    EBU21142 RIDING YOUR ATV...

  • Page 64: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EBU21619 Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01382 This ATV is intended for recreational use by expe- WARNING rienced operators only. This section, Riding your  Do not operate this ATV or allow anyone else ATV, provides general ATV riding instructions for to operate it without proper instruction.
  • Page 65 the time to learn the basic techniques well before This ATV is designed to carry the operator only attempting more difficult maneuvers. Become fa- – passengers prohibited. miliar with this ATV at slow speeds first, even if you The long seat is to allow the operator to shift posi- are an experienced operator.
  • Page 66 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 67 fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-4.) Pre-operation checks Always inspect your ATV each time you use it to...
  • Page 68  Do not exceed the maximum loading limits During operation for the vehicle (see “MAXIMUM LOADING Always keep your feet on the footrests during op- LIMIT” below or vehicle labeling). eration; otherwise, they may contact the rear  Make sure the load does not interfere with wheels.
  • Page 69 ATV should the engine has stopped. To reduce the risk of fire be genuine Yamaha or equivalent components during operation or after leaving the ATV, do not designed for use on this ATV and should be in- let brush, grass and other materials collect under stalled and used according to instructions.

  • Page 70: Be Careful Where You Ride

    next to other hot parts. Check under the vehicle BE CAREFUL WHERE YOU RIDE after operating in areas where combustible mate- This ATV is designed for use on unpaved surfaces rials may have collected. Do not idle or park the only.
  • Page 71 Watch carefully for other vehicles. Make sure you have enough time to react to hidden rocks, know your country’s laws and regulations before bumps, or holes. Go slowly and be extra care- you ride on unpaved public streets or roads. Do ful when operating on unfamiliar terrain.
  • Page 72 terrain could cause loss of traction or ATV con- trol, which could result in an accident, includ- ing an overturn. [EWB01542] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 73: Turning Your Atv

    NOTICE: Do not shift gears without Select a large, flat, unpaved area to become famil- trol. [EWB02632] iar with your ATV. Make sure that this area is free releasing the throttle. Damage to the engine or of obstacles and other riders. You should practice drive train may occur.
  • Page 74 To achieve maximum traction on unpaved surfac- es, 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 turning tech- nique must be used to allow the ATV to make turns quickly and easily.

  • Page 75: Climbing Uphill

     Shift your weight forward. Once you have learned this technique, you should  Never open the throttle suddenly or make be able to perform it at higher speeds or in tighter curves. sudden gear changes. The ATV could flip Improper riding procedures such as abrupt throt- over backwards.
  • Page 76 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 77 It is important when climbing a hill to make sure If you start to roll backwards, DO NOT apply the that your weight is transferred forward on the ATV. rear brake, and apply the front brake gradually. This can be accomplished by leaning forward and, The ATV could easily tip over backwards.

  • Page 78: Riding Downhill

     Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills.  Shift your weight backward and to the up side of the hill.

  • Page 79: Crossing A Slope

    Whenever possible, ride your ATV straight down- CROSSING A SLOPE hill. Avoid sharp angles which could allow the ATV EWB01633 WARNING to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- Improperly crossing hills or turning on hills stacles which may appear.

  • Page 80: Crossing Through Shallow Water

    As you travel across a slope, lean your body in the CROSSING THROUGH SHALLOW WATER uphill direction. It may be necessary to correct the EWB01642 WARNING steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on Operating this vehicle through deep or fast- slopes, be sure not to make sharp turns either up flowing water can lead to loss of control or an...
  • Page 81 After riding your ATV in water, be sure to drain the Test your brakes after leaving the water. If neces- trapped water by removing the check hose at the sary, apply them several times to let friction dry bottom of the air filter case. NOTICE: Undrained out the linings.

  • Page 82: Riding Over Rough Terrain

    accident. Be sure to keep your feet firmly mounted on the footrests 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 83: 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 If the rear wheels of your ATV start to slide side- should be chosen carefully before attempting ways, control can usually be regained (if there is...

  • Page 84: 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 85: 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 86: Owner's Manual And Tool Kit

    Make sure to protect the owner’s If you do not have the tools or experience required manual by putting it in the plastic bag, then by for a particular job, have a Yamaha dealer perform placing the bag in the document pouch. it for you.

  • Page 87: 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 mileage 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 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 89: 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 mileage 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 90 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses •...
  • Page 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours √ √ √ Drive chain roller • Check for wear and replace if necessary. • Make sure that all nuts, bolts, and screws are √...
  • Page 92 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours Moving parts and √ √ √ √ • Lubricate. cables • Check operation. • Check throttle lever free play, and adjust if neces- √...
  • Page 93 • Replace the brake hoses every four years and if cracked or damaged.

  • Page 94: Removing And Installing The Cowling And Panels

    EBU30131 Removing and installing the cowling and panels The cowling 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 95 5. Install the fuel tank cap by turning it clock- wise. To install the panel 1. Remove the fuel tank cap by turning it coun- terclockwise. 2. Place the panel in the original position, and then install the quick fasteners. NOTICE: When installing the panel, be sure not to pinch the cables or wires.
  • Page 96 Panels B and C To remove a panel 1. Remove panel A. 2. Pull the panel off. 2. Install panel A. Cowling To remove the cowling 1. Remove panels A, B and C. To install a panel 2. Loosen the quick fasteners, and then take the 1.

  • Page 97: Checking The Spark Plug

    The spark plug is an important engine component, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- 1.

  • Page 98: Engine Oil And Oil Filter Element

    Specified spark plug: Tightening torque: NGK/CR8E Spark plug: 13 N·m (1.3 kgf·m, 9.6 lb·ft) Before installing the spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. 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.
  • Page 99 To achieve the proper engine oil temperature for an accurate oil level reading, the engine must have first completely cooled down, and then warmed up again for several minutes to normal operating temperature. 3. Remove the engine oil tank filler cap, and wipe the engine oil dipstick off with a clean rag.
  • Page 100 When adding oil, be careful not to overfill the en- gine oil tank; the oil level rises faster starting from the half-level mark on the dipstick. 6. Check the O-ring for damage, and replace it if necessary. 7. Insert the dipstick into the engine oil tank filler hole, and then tighten the engine oil tank filler cap.
  • Page 101 1. Engine oil tank drain bolt 1. Crankcase engine oil drain bolt 2. Gasket 2. Gasket 6. Remove the crankcase engine oil drain bolt and its gasket. Skip steps 7–10 if the oil filter element is not being replaced. 7. Remove the oil filter element cover by remov- ing the bolts.
  • Page 102 1. Oil filter element cover 1. Oil filter element 2. Bolt 2. O-ring 8. Remove the oil filter element and the O-rings. 9. Install a new oil filter element and new O- rings. Make sure that the O-rings are properly seated. 10.
  • Page 103 11. Install the crankcase engine oil drain bolt, the ECB00301 NOTICE engine oil tank drain bolt and their new gas-  In order to prevent clutch slippage (since the ket, and then tighten the bolts to their speci- fied torques. engine oil also lubricates the clutch), do not mix any chemical additives.

  • Page 104: Coolant

    The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer change the coolant. WARNING! Never attempt to remove the radiator cap when the engine is hot.

  • Page 105: Cleaning The Air Filter Element

    Clean or, if necessary, replace has been added to the coolant, have a the air filter element more frequently if you are rid- Yamaha dealer check the antifreeze con- ing in unusually wet or dusty areas. tent of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced.
  • Page 106 2. Remove the seat. (See page 4-10.) 3. Remove the air filter case cover by unhooking the holders. 1. Air filter element 2. Washer 3. Wing bolt 1. Air filter case cover 6. Remove the wing bolt and washer from the air 2.
  • Page 107 10. Check the sponge material and replace it if 2. Air filter element frame damaged. 11. Apply Yamaha foam air filter oil or other qual- 8. Wash the sponge material gently but thor- ity foam air filter oil to the sponge material.
  • Page 108 1. Air filter element seat 1. Washer 14. Install the washer onto the air filter element 15. Insert the air filter element into the air filter frame, and then insert the wing bolt into the case, and then tighten the wing bolt. hole in the air filter element frame.

  • Page 109: Cleaning The Spark Arrester

    17. Install the seat. The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas. Each time the air filter element main- tenance is performed, check the air inlet of the air filter case for obstructions.
  • Page 110 1. Bolt 1. Tailpipe 2. Retainer 2. Spark arrester 3. Tailpipe 4. Install the gasket, tailpipe, and retainer and 4. Gasket align the bolt holes. 3. Tap the tailpipe lightly, and then use a wire 5. Install the bolts and tighten them to the spec- brush to remove any carbon deposits from ified torque.

  • Page 111: Adjusting The Throttle Lever Free Play

    EBU29704 Tightening torque: Adjusting the throttle lever free play Tailpipe cover bolt: 8 N·m (0.8 kgf·m, 5.9 lb·ft) EWB02342 WARNING Always let the exhaust system cool prior to touching exhaust components. Do not start the engine with the spark arrester removed.

  • Page 112: Valve Clearance

    If a brake pad has worn to the point must be adjusted by a Yamaha dealer at the inter- that the wear indicator grooves have almost dis- vals specified in the periodic maintenance and lu- appeared, have a Yamaha dealer replace the brication chart.

  • Page 113: Checking The Brake Fluid Level

    If a brake pad has worn to the point that the wear indicator grooves have almost dis- appeared, have a Yamaha dealer replace the brake pads as a set. 8-29...
  • Page 114 Front brake To check the rear brake fluid level, remove the seat. (See page 4-10.) Specified brake fluid: DOT 4 EWB02721 WARNING Improper maintenance can result in loss of braking ability. Observe these precautions:  Insufficient brake fluid may allow air to enter 1.

  • Page 115: Changing The Brake Fluid

    There should be no free play at the brake lever Have a Yamaha dealer change the brake fluid at end. If there is free play, have a Yamaha dealer in- the intervals specified in the periodic maintenance spect the brake system.

  • Page 116: Checking The Brake Pedal Height

    47–51 mm (1.85–2.01 in) brake pedal is not positioned as specified, have a Periodically check the cable length “A” and adjust Yamaha dealer adjust it. if necessary. 1. Release the parking brake by moving the parking brake lever to the right.
  • Page 117 If the cable length cannot be adjusted to specifi- again. cation, consult a Yamaha dealer. 6. Tighten the locknut on the brake cable. 7. Slide the rubber cover to its original position. 8-33...

  • Page 118: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the front brake light switch 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 119: Drive Chain Slack

    If the specified free play cannot be obtained as de- 3. Slide back the rubber cover at the clutch ca- scribed above or if the clutch does not operate ble. correctly, have a Yamaha dealer check the internal clutch mechanism. EBU26866 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary.
  • Page 120 4. Hole To adjust the drive chain slack 1. Place the ATV on a level surface. A rod can be obtained at a Yamaha dealer to make 2. Loosen the rear wheel axle pinch bolts. this adjustment. 3. Insert a rod of a diameter of 8 mm (0.3 in) and a length of 10 cm (4 in) into one of the holes in 4.

  • Page 121: Lubricating The Drive Chain

    prevent this from occurring, keep the drive EBU24883 Lubricating the drive chain chain slack within the specified limits. The drive chain must be cleaned and lubricated at [ECB00543] the intervals specified in the periodic maintenance 6. Pull the rod out, and then tighten the rear axle and lubrication chart, otherwise it will quickly wear pinch bolts to the specified torque in the or- out, especially when riding in dusty or wet areas.

  • Page 122: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Yamaha cable lubricant or other suitable cable lubricant EWB02582 WARNING  Inspect cables frequently and replace if damaged. Corrosion can result when the ca- 1.

  • Page 123: Checking And Lubricating The Brake And Clutch Levers

    Brake lever Checking the shift pedal The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle. 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.

  • Page 124: Checking The Wheel Hub Bearings

    Lithium-soap-based grease EBU24996 Lubricating the swingarm pivots The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the pe- EBU24964 riodic maintenance and lubrication chart. Checking the wheel hub bearings The front and rear wheel hub bearings must be...

  • Page 125: Lubricating The Upper And Lower Arm Pivots

    Left side EBU25035 1. Upper grease nipple Lubricating the upper and lower arm 2. Lower grease nipple pivots The upper and lower arm pivots must be lubricat- ed at the intervals specified in the periodic main- tenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 8-41...

  • Page 126: Lubricating The Steering Shaft

     It is recommended to have the battery serviced Lubricating the steering shaft by a Yamaha dealer. 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...
  • Page 127 3. Disconnect the negative battery lead first, EWB02161 WARNING then the positive battery lead by removing their bolt. NOTICE: When removing the bat- Battery electrolyte is poisonous and danger- tery, the main switch must be off, and the ous, as it contains sulfuric acid, which can cau- se severe burns.
  • Page 128 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 129: Replacing The Fuse

    EBU29962 Replacing the fuse 1. Positive battery lead (red) 2. Negative battery lead (black) 1. Fuse 3. Install the battery holding plate by installing 2. Spare fuse the bolts. The fuse holder is located under the seat. (See 4. Install the seat. (See page 4-10.) page 4-10.) If the fuse is blown, replace it as follows.

  • Page 130: Replacing A Headlight Bulb

    2. Remove the bulb cover. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU30873 Replacing a headlight bulb If a headlight bulb burns out, replace it with the specified bulb as follows.
  • Page 131 3. Remove the socket by pushing it in and turn- ing it counterclockwise, and then remove the burnt-out bulb. 1. Do not touch the glass part of the bulb. 5. Install the socket by pushing it in and turning it clockwise. 1.

  • Page 132: Adjusting A Headlight Beam

    EBU25562 Adjusting a headlight beam ECB00691 NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting bolt in direction (a). To lower a headlight beam, turn the adjusting bolt 1.

  • Page 133: Tail/Brake Light

    If the tail/brake light does not come on, have a and then install the wheel nuts. Yamaha dealer check it. EBU25652 Removing a wheel 1. Place the ATV on a level surface.

  • Page 134: 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 135: 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 136 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

  • Page 137: Cleaning And Storage

    EBU25861 CLEANING AND STORAGE ter pressure may cause water seepage EBU25903 Cleaning and deterioration of wheel bearings, Frequent, thorough cleaning of your ATV will not brakes, transmission seals and electrical only enhance its appearance but will improve its devices. Many expensive repair bills have general performance and extend the useful life of resulted from improper high-pressure de- many components.

  • Page 138: Storage

    abrasives which may mar the paint or protec- 3. Fill up the fuel tank and add fuel stabilizer (Fu- tive finish. When finished cleaning, start the el Med Rx if available), and then run the en- engine and let it idle for several minutes. gine for 5 minutes to distribute the treated fuel.
  • Page 139 6. Put the frame on stands or blocks to raise all wheels off the ground. (Alternatively, turn the wheels each month to prevent the tires from degrading in one spot.) 7. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.

  • Page 140: Specifications

    EBU25962 SPECIFICATIONS Dimensions: Vibration on seat (EN1032, ISO5008): Will not exceed 0.5 m/s² Overall length: Uncertainty of measurement: 1795 mm (70.7 in) 0.1 m/s² Overall width: Vibration on handle (EN1032, ISO5008): 1240 mm (48.8 in) Will not exceed 2.5 m/s² Overall height: Uncertainty of measurement: 1065 mm (41.9 in)
  • Page 141 Type: Fuel: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- Recommended fuel: Premium unleaded gasoline only Fuel tank capacity: 130 ˚F 10.0 L (2.64 US gal, 2.20 Imp.gal) Fuel reserve amount: SAE 5W-30 3.4 L (0.90 US gal, 0.75 Imp.gal) Fuel injection: SAE 10W-30 Throttle body:...
  • Page 142 Gear ratio: Loading: 1st: Maximum loading limit: 35/14 (2.500) 100.0 kg (220 lb) 2nd: (Total weight of rider, cargo, accessories, and tongue) 30/15 (2.000) Tire air pressure (measured on cold tires): 3rd: Recommended: 31/19 (1.632) Front: 4th: 35.0 kPa (0.350 kgf/cm², 5.0 psi) 28/21 (1.333) Rear: 5th:...
  • Page 143 Specified brake fluid: Voltage, capacity: DOT 4 12 V, 6.0 Ah Rear brake: Headlight(s): Type: Bulb type: Hydraulic disc brake Krypton bulb Bulb voltage, wattage × quantity: Operation: Right foot operation Headlight: 12 V, 30.0/30.0 W × 2 Specified brake fluid: DOT 4 Tail/brake light: Front suspension:...
  • Page 144 whether or not further precautions are required. Factors that influence the actual level of exposure of work-force include the characteristics of the work room, the other sources of noise, etc. i.e. the number of machines and other adjacent process- es, and the length of time for which an operator is exposed to the noise.

  • Page 145: Consumer Information

    Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 146 1. Model label 11-2...

  • Page 147: Index

    INDEX Drive chain slack ............8-35 Accessories and loading ..........6-5 Air filter element, cleaning ........... 8-21 Engine break-in .............. 6-4 Engine oil ............... 5-4 Engine oil and oil filter element ........8-14 Battery ................. 8-42 Engine, start ..............6-1 Brake and clutch levers, checking and lubricating ..
  • Page 148 Model label ..............11-1 Tail/brake light ............. 8-49 Neutral indicator light .............4-1 Throttle lever ............4-4, 5-5 Throttle lever free play, adjusting .........8-27 Tires ................5-5 Owner’s manual and tool kit ..........8-2 Troubleshooting ............8-50 Troubleshooting charts ..........8-51 Parking ................6-4 Parking brake free play, adjusting .......8-32 Valve clearance ............
  • Page 150 EBU26173 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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