User manual YAMAHA WOLVERINE 450 4X4-2006

READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM45FXV WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-19-42 3C2-F8199-10 EBU00776 EBU13320 1- INTRODUCTION Congratulations on your purchase of the Yamaha YFM45FXV. It represents the result 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. This manual will provide you with a good basic understanding of the features and operation of this ATV. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: G READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. G PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. G NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION. G THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE. G THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT TYPE RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS. EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. A NOTE provides key information to make procedures easier or clearer. CAUTION: NOTE: EBU26300 *Product and specifications are subject to change without notice. EBU15000 1- IMPORTANT NOTICE This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. 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. EBU01067 AFFIX DEALER LABEL HERE YFM45FXV OWNER'S MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11626-19-42 EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1 SAFETY INFORMATION.................. 2-1 DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2 Key identification number................ 3-2 Vehicle identification number .......... 3-3 Model label ...................................... 3-3 CONTROL FUNCTIONS .................. 4-1 Main switch...................................... 4-1 2 3 Indicator and warning lights .............4-2 Speedometer unit ............................4-3 Handlebar switches .........................4-4 Throttle lever ....................................4-7 Speed limiter ....................................4-8 Front brake lever..............................4-9 Brake pedal and rear brake lever ...............................................4-9 Drive select lever ...........................4-10 Fuel tank cap .................................4-10 Fuel cock........................................4-11 Starter (choke) ...............................4-12 Seat................................................4-13 Storage compartment ....................4-14 Front shock absorber adjustment ...................................4-15 Rear shock absorber adjustment ...................................4-17 5 PRE-OPERATION CHECKS ............5-1 Front and rear brakes ......................5-2 Fuel ..................................................5-4 Engine oil .........................................5-6 4 Final gear oil.................................... 5-6 Differential gear oil .......................... 5-6 Coolant............................................ 5-7 Throttle lever ................................... 5-7 Fittings and fasteners...................... 5-8 Lights............................................... 5-8 Switches.......................................... 5-8 Tires ................................................ 5-8 How to measure tire pressure....... 5-10 Tire wear limit................................ 5-11 6 OPERATION..................................... 6-1 Starting a cold engine ..................... 6-1 Starting a warm engine................... 6-3 Warming up..................................... 6-3 Drive select lever operation and reverse driving............................... 6-4 Engine break-in............................... 6-7 Parking ............................................ 6-8 Parking on a slope .......................... 6-9 Accessories and loading............... 6-10 7 RIDING YOUR ATV .......................... 7-1 Getting to know your ATV ............... 7-3 Ride with care and good judgement...................................... 7-4 Be careful where you ride.............. 7-16 Turning your ATV .......................... 7-22 Climbing uphill ............................... 7-24 Riding downhill .............................. 7-30 Crossing a slope............................ 7-32 Crossing through shallow water .... 7-34 Riding over rough terrain............... 7-37 Sliding and skidding....................... 7-38 What to do if................................... 7-40 What to do ..................................... 7-40 PERIODIC MAINTENANCE AND ADJUSTMENT .................................. 8-1 Owner's manual and tool kit............ 8-1 Periodic maintenance chart for the emission control system.......... 8-3 General maintenance and lubrication chart ............................. 8-4 8 Removing and installing cowlings and panels..................................... 8-6 Engine oil and oil filter cartridge .... 8-14 Final gear oil .................................. 8-19 Differential gear oil replacement ... 8-22 Cooling system.............................. 8-24 Changing the coolant .................... 8-26 Axle boots...................................... 8-29 Spark plug inspection.................... 8-30 Air filter element cleaning.............. 8-32 V-belt cooling duct check hose ..... 8-35 V-belt case drain plug.................... 8-36 Spark arrester cleaning ................. 8-36 Carburetor adjustment................... 8-38 Idle speed adjustment ................... 8-38 Valve clearance adjustment .......... 8-39 Select lever safety system cable adjustment ......................... 8-39 Throttle lever adjustment............... 8-40 Front brake pad check .................. 8-40 Rear brake pad check ................... 8-41 Inspecting the brake fluid level...... 8-42 Brake fluid replacement................. 8-43 Front brake lever free play.............8-44 Adjusting the rear brake lever and brake pedal ..................................8-45 Adjusting the rear brake light switch ...........................................8-47 Cable inspection and lubrication.....................................8-48 Lubricating the brake levers and brake pedal ..................................8-48 Wheel removal...............................8-49 Wheel installation...........................8-50 Battery............................................8-51 Battery maintenance......................8-52 Fuse replacement ..........................8-53 Replacing a headlight bulb ............8-55 Headlight beam adjustment...........8-58 Tail/brake light bulb replacement .................................8-58 Troubleshooting .............................8-59 Troubleshooting charts ..................8-61 9 CLEANING AND STORAGE............ 9-1 A. Cleaning...................................... 9-1 B. Storage ....................................... 9-3 SPECIFICATIONS.......................... 10-1 NOISE REGULATION.................... 11-1 MAINTENANCE RECORD ............ 12-1 ATV LIMITED WARRANTY............ 13-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................... 14-1 10 11 12 13 14 EBU00464 1- LOCATION OF THE WARNING AND SPECIFICATION LABELS 1-1 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1-2 2 3 WARNING UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. YAMAHA 4XE-F415A-00 4 1-3 5 1-4 EBU13361 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: G Read this manual and all labels carefully and follow the operating procedures described. G Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you. G Always follow the age recommendation: - A child under 16 years old should never operate an ATV with engine size greater than 90cc. G Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely. G Never carry a passenger on an ATV. G Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. G Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 2-1 G G G G G G G G G G Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or a jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. 2-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 G G G G G Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed. Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible. Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. 2-3 G G G G G G G Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings. Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Always use the size and type of tires specified in this manual. Always maintain proper tire pressure as described in this manual. Never modify an ATV through improper installation or use of accessories. Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor's Safety Hotline at 1-800-852-5344. 2-4 WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers. When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the "OFF" position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. 2-5 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation. 2-6 EBU00032 1- DESCRIPTION AND MACHINE IDENTIFICATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Spark arrester Tail/brake light Spark plug Rear brake fluid reservoir Radiator cap Front shock absorber assembly spring preload adjusting ring Brake pedal V-belt case Fuel cock Air filter case Fuses Storage compartment and tool kit Seat lock lever Rear shock absorber assembly spring preload adjusting ring Engine oil dipstick Oil filter cartridge Coolant reservoir V-belt cooling duct check hose Rear brake lever Left handlebar switches Starter (choke) Drive select lever Main switch Speedometer unit Fuel tank cap On-Command four-wheel drive switch 27. Front brake lever 28. Throttle lever 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual. 3-1 EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: Key identification number The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key. 1 2 3 4 5 6 7 8 2. VEHICLE IDENTIFICATION NUMBER: 9 10 1. Key identification number 11 12 13 14 3. MODEL LABEL INFORMATION: 3-2 EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 1. Model label 3-3 EBU00039 1- CONTROL FUNCTIONS 1 2 3 4 WARNING Indicates a potential hazard that could result in serious injury or death. EBU09420 5 6 1. Main switch Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position. 7 8 9 10 11 12 13 14 4-1 EBU08020 EBU00860 Indicator and warning lights Coolant temperature warning light " " When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes. CAUTION: _ G 1. 2. 3. 4. 5. Coolant temperature warning light " " Neutral indicator light "N" Reverse indicator light "R" Park indicator light "P" Four-wheel-drive indicator light " " G The engine may overheat if the ATV is overloaded. If this happens, reduce the load to specification. After restarting, make sure that the light is out. Continuous use while the light is on may cause damage to the engine. _ EBU09720 Neutral indicator light "N" This indicator light comes on when the drive select lever is in the "N" position. 4-2 EBU12500 EBU26181 Reverse indicator light "R" This indicator light comes on when the drive select lever is in the "R" position. EBU00609 Speedometer unit Park indicator light "P" This indicator light comes on when the drive select lever is in the "P" (park) position. EBU06050 Four-wheel-drive indicator light " " This indicator light comes on when the 2WD/ 4WD switch is in the 4WD position. NOTE: Due to the synchronizing mechanism in the differential gear case, the light may not come on until the ATV starts moving. _ _ 1. Speedometer 3. "SELECT" button 2. Odometer/Tripmeter The speedometer unit is equipped with the following: G a speedometer (which shows the riding speed) G an odometer (which shows the total distance traveled) G a tripmeter (which show the distance traveled since it was last set to zero) 4-3 EBU00053 Odometer and tripmeter modes Pushing the "SELECT" button switches the display between the odometer mode "ODO" and the tripmeter mode "TRIP" in the following order: ODOTRIPODO To reset the tripmeter, select it by pushing the "SELECT" button, and then push the "SELECT" button for at least two seconds. The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops. NOTE: Pushing in the "SELECT" button, then turning the key to "ON", and keeping them in this position for at least two seconds switches the display between "mph" and "km/h". _ _ Handlebar switches 1. Light switch " / /OFF" 2. Engine stop switch " / " 3. Start switch " " EBU12040 Light switch " / /OFF" Set the switch to " " to turn on the low beam and the taillight. Set the switch to " " to turn on the high beam and the taillight. Set the switch to "OFF" to turn off all the lights. 4-4 EBU00607 CAUTION: _ Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. _ Start switch " " The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine. (See page 6-1 for details.) EBU12050 Engine stop switch " / " Make sure that the engine stop switch is set to " " before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not start or run when the engine stop switch is set to " ". 4-5 WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving. WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD in some circumstances. Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and increase the risk of losing control and an accident. HOW TO AVOID THE HAZARD Always stop the ATV before changing from 2WD to 4WD or vice-versa. 1. On-Command four-wheel drive switch "2WD/4WD" EBU00601 On-Command four-wheel drive switch "2WD/4WD" To change from two-wheel drive (2WD) to four-wheel drive (4WD), stop the ATV and set the switch to the 4WD position. To change from four-wheel drive (4WD) to two-wheel drive (2WD), stop the ATV and set the switch to the 2WD position. 4-6 EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. WARNING POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can't find or solve the problem yourself. 1. Throttle lever 4-7 EBU01159 Speed limiter The speed limiter keeps the throttle from 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. WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3­5 mm (0.12­0.20 in). See page 8-40. 1. Locknut 2. Adjusting screw a. No more than 12 mm (0.47 in) 4-8 EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Brake pedal 1. Front brake lever EBU00732 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. Push down on the pedal or pull the lever toward the handlebar to apply the rear brake. 1. Rear brake lever 4-9 EBU15200 EBU00092 Drive select lever The drive select lever is used to shift your machine into the forward, neutral, reverse and park positions. (Refer to page 6-4 for the drive select lever operation.) Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Fuel tank cap 1. Drive select lever 4-10 EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY. After refuelling, return the fuel cock lever to the "ON" position. OFF Position 1. Arrow mark positioned over "OFF" ON Position 1. Arrow mark positioned over "ON" 4-11 EBU00095 RES Position 1. Arrow mark positioned over "RES" Starter (choke) " " Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to "Starting a cold engine" for proper operation. (See page 6-1.) 1. Starter (choke) " " 4-12 EBU26200 Seat To remove the seat, push the seat lock lever backward and pull up the seat at the rear. 1. Seat lock lever 1. Seat 4-13 EBU26230 To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. _ _ Storage compartment Maximum load limit: 2.0 kg (4 lb) The storage compartment is located under the seat. (See page 4-13 for seat removal and installation procedures.) When storing any documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartment. NOTE: If any water collects in the storage compartment, remove the drain plugs at the bottom of the storage compartment, drain the water, and then install the drain plugs. _ _ 1. Projection (× 2) 2. Seat holder (× 2) 4-14 EBU01104 Front shock absorber adjustment The spring preload can be adjusted to suit the rider's weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b. 1. Storage compartment 1. Spring preload adjusting ring 2. Position indicator 1. Storage compartment drain plug (× 2) 4-15 NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. _ _ WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting. Standard position: 2 1 - Minimum (soft) 5 - Maximum (hard) 1. Special wrench 4-16 EBU01103 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider's weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b. NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. _ _ Standard position: 2 1 - Minimum (soft) 5 - Maximum (hard) 1. Spring preload adjusting ring 2. Position indicator 1. Special wrench 4-17 EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death. 4-18 1- PRE-OPERATION CHECKS 1 2 Before using this machine, check the following points: ITEM Front brake Rear brake Fuel Engine oil Coolant reservoir Final gear oil and differential gear oil Throttle Wheels and tires Fittings and fasteners Lights and switches Axle boots ROUTINE · Check operation, lever free play, fluid level and fluid leakage. · Fill with DOT 4 brake fluid if necessary. · Check operation, lever free play, fluid level and fluid leakage. · Fill with DOT 4 brake fluid if necessary. · Check fuel level. · Fill with fuel if necessary. · Check oil level. · Fill with oil if necessary. · Check coolant level in reservoir. · Fill with coolant if necessary. · Check for leakage. · Check for proper throttle cable operation and free play. · Check tire pressure, wear and damage. · Check all fittings and fasteners. · Check for proper operation. · Check for damage. PAGE 5-2­5-3, 8-40, 8-42­8-44 5-2­5-3, 8-41­8-43, 8-45­8-46 5-4­5-5 5-6, 8-14­8-19 5-7, 8-24­8-29 5-6, 8-19­8-24 5-7, 8-40 5-8­5-11, 8-49­8-50 5-8 5-8, 8-47, 8-55­8-59 8-29 3 4 5 6 7 8 9 10 11 12 13 14 5-1 EBU11011 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. Front and rear brakes Brake levers and brake pedal G Check that there is no free play in the front brake lever. If there is free play, have a Yamaha dealer adjust it. G Check for correct free play in the rear brake lever. If the free play is incorrect, adjust it. (See page 8-45.) G Check for correct brake pedal height. If the pedal height is incorrect, have a Yamaha dealer adjust it. G Check the operation of the brake levers and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have a Yamaha dealer inspect the brake system. Brake fluid level Check the brake fluid level. Add fluid if necessary. (See pages 8-42­8-43.) Recommended brake fluid: DOT 4 5-2 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be inspected by a Yamaha dealer. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brake pads for wear. (See pages 8-40­8-41.) WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have a Yamaha dealer check for the cause. 5-3 EBU01085 Fuel Make sure there is sufficient gasoline in the tank. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total: 14.5 L (3.19 Imp gal, 3.83 US gal) Reserve: 4.5 L (0.99 Imp gal, 1.19 US gal) Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost. CAUTION: _ 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. _ 5-4 Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot. 1. Fuel level 2. Fuel tank filler tube 5-5 EBU10842 EBU00493 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-14­ 8-19.) Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-19­ 8-22 for details.) Recommended oil: SAE 80 API GL-4 Hypoid gear oil If desired, an SAE 80W90 hypoid gear oil may be used for all conditions. NOTE: GL-4 is a quality and additive rating, GL-5 or GL-6 rated hypoid gear oils may also be used. CAUTION: _ G G _ In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of "CD" or oils of a higher quality than specified. In addition, do not use oils labeled "ENERGY CONSERVING II" or higher. Make sure that no foreign material enters the crankcase. EBU00678 Recommended engine oil type and quantity: See page 10-2. Differential gear oil Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-22­8-24 for details.) Recommended oil: SAE 80 API GL-4 Hypoid gear oil 5-6 EBU12530 Coolant Check the coolant level in the coolant reservoir when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir. If the coolant level is at or below the minimum level mark, add distilled water to bring the level up to maximum level mark. Change the coolant every two years. (See pages 8-24­8-29 for details.) WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. CAUTION: _ Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. _ EBU01083 Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.22 Imp qt, 0.26 US qt) Throttle lever Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation. 5-7 EBU11620 EBU00157 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. EBU10030 Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD 1. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recommended. ACE-01E Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation. EBU11700 Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation. Manufacturer Front Rear MAXXIS MAXXIS Size AT23 × 8R12 AT23 × 10R12 Type M937 M938 5-8 2. The tires should be set to the recommended pressure: G Recommended tire pressure Front 40 kPa (0.40 kgf/cm2, 5.8 psi) Rear 40 kPa (0.40 kgf/cm2, 5.8 psi) G Check and adjust tire pressures when the tires are cold. G Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 37 kPa (0.37 kgf/cm2, 5.3 psi) Rear 37 kPa (0.37 kgf/cm2, 5.3 psi) 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. 5-9 EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure with tires cold. Set tire pressures to the following specifications: ACE-02EACE-02E Recommended pressure Front 40 kPa (0.40 kgf/cm2, 5.8 psi) 40 kPa (0.40 kgf/cm2, 5.8 psi) Minimum 37 kPa (0.37 kgf/cm2, 5.3 psi) 37 kPa (0.37 kgf/cm2, 5.3 psi) Maximum 43 kPa (0.43 kgf/cm2, 6.1 psi) 43 kPa (0.43 kgf/cm2, 6.1 psi) 1. Low-pressure tire gauge Rear 5-10