User manual YAMAHA WOLVERINE 450 4X4-2007

READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM45FXW WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-20-38 3C2-F8199-11 EBU17091 EBU17170 INTRODUCTION EBU17300 Congratulations on your purchase of the Yamaha YFM45FXW. This ATV 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 the 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 90 cc, 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. EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 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! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or repairing the ATV. A CAUTION indicates special precautions that must be taken to avoid damage to the ATV. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE: * Product and specifications are subject to change without notice. EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! 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. EBU17401 AFFIX DEALER LABEL HERE YFM45FXW OWNER'S MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2006 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-11626-20-38 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17420 TABLE OF CONTENTS SAFETY INFORMATION .............................. 1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 2-1 DESCRIPTION .............................................. 3-1 Left view ...................................................... 3-1 Right view.................................................... 3-1 Controls and instruments ............................ 3-2 INSTRUMENT AND CONTROL FUNCTIONS .................................................. 4-1 Main switch ................................................ 4-1 Indicator lights and warning light ................ 4-2 Speedometer unit ....................................... 4-3 Handlebar switches .................................... 4-4 Throttle lever .............................................. 4-6 Speed limiter ...............................................4-7 Front brake lever .........................................4-8 Brake pedal and rear brake lever ...............4-8 Drive select lever ........................................4-9 Fuel tank cap ..............................................4-9 Fuel ...........................................................4-10 Fuel cock ..................................................4-11 Starter (choke) ..........................................4-13 Seat ..........................................................4-13 Storage compartment ...............................4-14 Adjusting the front shock absorber assemblies ..............................................4-15 Adjusting the rear shock absorber assembly .................................................4-17 PRE-OPERATION CHECKS ..........................5-1 Pre-operation check list ..............................5-1 Fuel .............................................................5-4 Engine oil ....................................................5-4 Final gear oil ...............................................5-4 Differential gear oil ......................................5-4 Coolant .......................................................5-4 Front and rear brakes .................................5-5 Throttle lever ...............................................5-6 Tires ............................................................5-6 Measuring the tire pressure ........................5-7 Tire wear limit .............................................5-8 Chassis fasteners ....................................... 5-9 Instruments, lights and switches ................ 5-9 OPERATION .................................................. 6-1 Starting a cold engine ................................ 6-1 Starting a warm engine .............................. 6-3 Operating the drive select lever and driving in reverse ...................................... 6-3 Engine break-in .......................................... 6-5 Parking ....................................................... 6-6 Parking on a slope ..................................... 6-6 Accessories and loading ............................ 6-7 RIDING YOUR ATV ...................................... 7-1 GETTING TO KNOW YOUR ATV............... 7-2 RIDE WITH CARE AND GOOD JUDGEMENT............................................ 7-3 BE CAREFUL WHERE YOU RIDE........... 7-13 TURNING YOUR ATV .............................. 7-17 CLIMBING UPHILL ................................... 7-19 RIDING DOWNHILL.................................. 7-23 CROSSING A SLOPE............................... 7-25 CROSSING THROUGH SHALLOW WATER ................................................... 7-27 RIDING OVER ROUGH TERRAIN ........... 7-29 SLIDING AND SKIDDING......................... 7-30 WHAT TO DO IF... .................................... 7-31 WHAT TO DO............................................7-32 PERIODIC MAINTENANCE AND MINOR REPAIR ..........................................................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 ........................................8-5 Removing and installing cowlings and panels .......................................................8-9 Checking the spark plug ...........................8-15 Engine oil and oil filter cartridge ................8-17 Final gear oil .............................................8-22 Changing the differential gear oil ..............8-24 Coolant .....................................................8-26 Cleaning the air filter element ...................8-31 Cleaning the spark arrester ......................8-34 V-belt cooling duct check hose .................8-35 V-belt case drain plug ...............................8-35 Adjusting the carburetor ............................8-36 Adjusting the engine idling speed .............8-36 Adjusting the throttle cable free play .........8-37 Valve clearance ........................................8-38 Adjusting the drive select lever safety system cable ...........................................8-38 Checking the front and rear brake pads ...8-38 Checking the brake fluid level .................. 8-39 Changing the brake fluid .......................... 8-41 Checking the front brake lever free play ................................................. 8-41 Adjusting the rear brake lever free play and checking the brake pedal position ............................... 8-42 Axle boots ................................................ 8-44 Brake light switches ................................. 8-44 Checking and lubricating the cables ........ 8-45 Checking and lubricating the front and rear brake levers .................................... 8-46 Checking and lubricating the brake pedal ...................................................... 8-46 Checking the wheel bearings ................... 8-47 Lubricating the drive shaft universal joint ......................................................... 8-47 Lubricating the steering shaft ................... 8-47 Battery ...................................................... 8-47 Replacing a fuse ....................................... 8-49 Replacing a headlight bulb ....................... 8-51 Adjusting a headlight beam ...................... 8-53 Replacing the tail/brake light bulb ............ 8-53 Removing a wheel .................................... 8-54 Installing a wheel ...................................... 8-55 Troubleshooting ....................................... 8-56 Troubleshooting charts ............................. 8-57 CLEANING AND STORAGE ..........................9-1 Cleaning ......................................................9-1 Storage .......................................................9-2 SPECIFICATIONS .......................................10-1 CONSUMER INFORMATION.......................11-1 Identification numbers ...............................11-1 Noise regulation ........................................11-3 Maintenance record ..................................11-4 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY .........11-5 YAMAHA EXTENDED SERVICE (Y.E.S.) ...................................................11-7 EBU17430 SAFETY INFORMATION EBU17513 1 G 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 1800-887-2887 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 90 cc. 1-1 G G G G G G 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. Never carry a passenger on an ATV. Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 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 riding 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. G 1 G G G G G 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 and never turn at excessive speeds. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. 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 1-2 G G G G 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. 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. G 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. G Always use the size and type of tires specified in this manual. G Always maintain proper tire pressure as described in this manual. G Never modify an ATV through improper installation or use of accessories. G 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. 1 1-3 EWB00021 WARNING 1 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, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. EWB00030 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. 1-4 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. 1 1-5 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 2 2-1 EBU17670 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 replacement label from your Yamaha dealer. 2 2-2 2 2-3 EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 3 1. Front shock absorber assembly spring preload adjusting ring 2. Fuel cock 3. Air filter case 4. Fuses 5. Storage compartment and tool kit 6. Seat lock lever 7. Rear shock absorber assembly spring preload adjusting ring 8. Engine oil filler cap 9. Oil filter cartridge 10.Coolant reservoir 11.V-belt cooling duct check hose 3-1 1. 2. 3. 4. 5. 6. 7. Spark arrester Tail/brake light Battery Spark plug Rear brake fluid reservoir Radiator cap Front shock absorber assembly spring preload adjusting ring 8. Brake light switch 9. Brake pedal 10.V-belt case drain plug EBU17712 Controls and instruments NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual. 3 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Drive select lever 5. Main switch 6. Speedometer unit 7. Fuel tank cap 8. Front brake fluid reservoir 9. On-Command four-wheel-drive switch 10.Front brake lever 11.Throttle lever 3-2 EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17760 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. OFF All electrical systems are off. The key can be removed. 4 1. Main switch 4-1 EBU17813 EBU17860 Indicator lights and warning light Neutral indicator light " " This indicator light comes on when the transmission is in the neutral position. EBU17920 4 Coolant temperature warning light " " This warning light comes on when the engine overheats. When this occurs during operation, stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes. ECB00010 1. 2. 3. 4. 5. Coolant temperature warning light " " Neutral indicator light "N" Reverse indicator light "R" Park indicator light "P" On-Command four-wheel-drive indicator " " EBU17840 CAUTION: The engine may overheat if the ATV is overloaded. In this case, reduce the load to specification. G Start the engine after making sure that the warning light is out. Continuous use while the warning light is on may cause damage to the engine. G EBU26591 Reverse indicator light " " This indicator light comes on when the transmission is in the reverse position. NOTE: If the indicator light flashes or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. 4-2 On-Command four-wheel-drive indicator " " This indicator comes on when the On-Command four-wheel-drive switch is set to the "4WD" position. NOTE: Due to the synchronizing mechanism in the differential gear case, the indicator may not come on until the ATV starts moving. EBU17970 Park indicator light " " This indicator light comes on when the transmission is in the park position. EBU26361 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 shows the distance traveled since it was last set to zero) 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: ODO TRIP ODO 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". 4 Speedometer unit 1. Speedometer 2. Odometer/tripmeter 3. "SELECT" button 4-3 EBU18061 EBU18100 Handlebar switches Start switch " " Push this switch to crank the engine with the starter. ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. 4 EBU18151 1. Light switch " / 2. Engine stop switch " 3. Start switch " " EBU18080 /OFF" / " Light switch " / /OFF" Set this switch to " " to turn on the low beams and the taillight. Set the switch to " " to turn on the high beams and the taillight. Set the switch to "OFF" to turn off all the lights. ECB00040 Engine stop switch " / " Set this switch to " " before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run when this switch is set to " ". CAUTION: Do not use the headlights with the engine turned off for an extended period of time, otherwise 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. 4-4 EBU28210 On-Command four-wheel-drive switch "2WD"/"4WD" This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice-versa. Select the appropriate drive according to the terrain and the conditions. G "2WD" (two-wheel drive): Power is supplied to the rear wheels. G "4WD" (four-wheel drive): Power is supplied to the rear and front wheels. To change from two-wheel drive to four-wheel drive, stop the ATV and push the switch in to the "4WD" position. Then, the four-wheel-drive indicator " " comes on in the speedometer unit display. To change from four-wheel drive to two-wheel drive, stop the ATV and push the switch in to the "2WD" position. 4 1. On-Command four-wheel-drive switch "2WD"/"4WD" 4-5 EWB00120 WARNING POTENTIAL HAZARD Changing from two-wheel drive to fourwheel drive or from four-wheel drive to twowheel drive while the ATV is moving. WHAT CAN HAPPEN The ATV handles differently in two-wheel drive than in four-wheel drive in some circumstances. Changing from two-wheel drive to four-wheel drive or from four-wheel drive to two-wheel drive while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and increase the risk of losing control and of causing an accident. HOW TO AVOID THE HAZARD Always stop the ATV before changing from two-wheel drive to four-wheel drive or viceversa. EBU18270 Regulate the speed of the ATV by varying the throttle position. Because the throttle is springloaded, the ATV will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. 4 1. 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. EWB00200 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. WARNING POTENTIAL HAZARD Malfunction of throttle. 4-6 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. EBU18311 4 Speed limiter Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (a). To decrease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b). 4-7 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in) 3. Tighten the locknut. EWB00190 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 3.0­5.0 mm (0.12­0.20 in). (See page 8-37.) EBU18391 4 1. Front brake lever EBU18442 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. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. Front brake lever The front brake lever is located on the right handlebar. To apply the front brake, pull the brake lever toward the handlebar grip. 4-8 EBU18621 Drive select lever The drive select lever is used to shift your ATV into the forward, neutral, reverse and park positions. See the "Operating the drive select lever and driving in reverse" section on page 6-3 for the drive select lever operation. 4 1. Brake pedal 1. Drive select lever EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Rear brake lever 4-9 4 1. Fuel tank cap EBU18730 1. Fuel level 2. Fuel tank filler tube Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 14.5 L (3.83 US gal) (3.19 Imp.gal) Fuel reserve amount: 4.5 L (1.19 US gal) (0.99 Imp.gal) 4-10 ECB00070 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. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a 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. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or ATV performance problems. EWB00270 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. EBU18820 4 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while also filtering it. The fuel cock lever positions are explained as follows and shown in the illustrations. WARNING POTENTIAL HAZARD Improper care when refueling. 4-11 OFF ON 4 1. Arrow mark positioned over "OFF" 1. Arrow mark positioned over "ON" With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding. 4-12 RES Move the starter (choke) in direction (b) to turn off the starter (choke). See the "Starting a cold engine" section on page 6-1 for proper operation. 4 1. Arrow mark positioned over "RES" This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to "ON"! EBU18850 1. Starter (choke) " EBU26981 " Seat To remove the seat Push the seat lock lever backward and pull up the seat at the rear. Starter (choke) " " Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the starter (choke) in direction (a) to turn on the starter (choke). 4-13 To install the seat Fit the slot in the seat onto the projection on the front cowling, insert the projections on the front of the seat into the seat holders, and then push on the seat at the rear. NOTE: Make sure that the seat is securely fitted. 4 1. Seat 1. Slot 2. Projection 3. Seat holder EBU26551 1. Seat lock lever Storage compartment The storage compartment is located under the seat. (See page 4-13.) 4-14 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. ECB00130 G Do not exceed the maximum load of 100.0 kg (220 lb) for the ATV. CAUTION: 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 storage compartment. NOTE: Drain plugs are fitted at the bottom of the storage compartment. If any water collects in the storage compartment, remove the drain plugs, drain the water, and then install the drain plugs. 4 1. Storage compartment drain plug EBU18980 Adjusting the front shock absorber assemblies 1. Storage compartment G Do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment. 4-15 The spring preload can be adjusted to suit the rider's weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. 4 1. Special wrench 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Spring preload setting: Minimum (soft): 1 Standard: 2 Maximum (hard): 5 EWB00350 WARNING POTENTIAL HAZARD Improper shock absorber assembly adjustment. 4-16 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 absorber assemblies on the left and right side to the same setting. EBU19020 4 Adjusting the rear shock absorber assembly The spring preload can be adjusted to suit the rider's weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-17 4 1. Special wrench Spring preload setting: Minimum (soft): 1 Standard: 2 Maximum (hard): 5 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4-18 EBU19200 PRE-OPERATION CHECKS EBU19210 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the "Periodic maintenance and lubrication chart" on page 8-3 to determine which service should be performed by a Yamaha dealer. ITEM Fuel ROUTINE · Check fuel level in fuel tank, and add recommended fuel if necessary. · Check fuel line for leakage. Correct if necessary. · Check oil level in engine, and add recommended oil to specified level if necessary. · Check ATV for oil leakage. Correct if necessary. · Check ATV for oil leakage. Correct if necessary. · Check ATV for oil leakage. Correct if necessary. · Check coolant level in reservoir, and add recommended coolant to specified level if necessary. · Check cooling system for leakage. Correct if necessary. · Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. · Check brake pads for wear, and replace if necessary. · Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary. · Check hydraulic system for leakage. Correct if necessary. PAGE 4-10, 5-4 5 Engine oil Final gear oil Differential gear oil Coolant 5-4, 8-17 5-4, 8-22 5-4, 8-24 5-4, 8-26 Front brake 5-5, 8-38, 8-39, 8-41 5-1 ITEM ROUTINE · Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. · Check lever free play, and adjust if necessary. · Check brake pads for wear, and replace if necessary. · Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary. · Check hydraulic system for leakage. Correct if necessary. · Make sure that operation is smooth. Lubricate cable and lever housing if necessary. · Check cable free play, and adjust if necessary. · Make sure that operation is smooth. Lubricate if necessary. · Check wheel condition, and replace if damaged. · Check tire condition and tread depth. Replace if necessary. · Check air pressure. Correct if necessary. · Make sure that operation is smooth. Lubricate pedal pivoting point if necessary. · Make sure that operation is smooth. Lubricate lever pivoting points if necessary. · Check for cracks or damage, and replace if necessary. · Make sure that all nuts, bolts and screws are properly tightened. · Check operation, and correct if necessary. PAGE Rear brake 5-5, 8-38, 8-39, 8-42 Throttle lever 5-6, 8-37 8-45 5-6, 5-7, 5-8 8-46 8-46 8-44 5-9 5-9 5 Control cables Wheels and tires Brake pedal Brake levers Axle boots Chassis fasteners Instruments, lights and switches EWB00470 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. 5-2 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 it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. 5 5-3 EBU19530 EBU19590 Fuel Make sure that there is sufficient fuel in the tank. (See page 4-10.) EWB00500 Final gear oil Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-22.) EBU19600 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. EBU19560 Differential gear oil Make sure that the differential gear oil is at the specified level. Add oil as necessary. (See page 8-24.) EBU19620 5 Coolant Make sure that the coolant is at the specified level. Add coolant as necessary. (See page 8-26.) NOTE: The coolant level must be checked on a cold engine since the level varies with engine temperature. EWB00490 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. Engine oil Make sure that the engine oil is at the specified level. Add oil as necessary. (See page 8-17.) 5-4 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. EBU19721 Brake fluid level Check the brake fluid level. Add fluid if necessary. (See page 8-39.) Recommended brake fluid: DOT 4 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 a lever moves slowly inward, there may be a leak in the brake system. 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. If the brakes do not provide proper braking performance, check the brake pads for wear. (See page 8-38.) 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 check the brake system. G Check for correct free play in the rear brake lever. If the free play is incorrect, adjust it. (See page 8-42.) 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 check the brake system. 5-5 5 EWB00540 EBU19801 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. EBU19761 Tires EWB00551 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 G The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model. Other tire combinations are not recommended. Front: Manufacturer/model: MAXXIS/M937 Size: AT23 x 8R12 Type: Tubeless 5 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary. 5-6 G Rear: Manufacturer/model: MAXXIS/M938 Size: AT23 x 10R12 Type: Tubeless The tires should be set to the recommended pressure: Recommended tire pressure: Front: 40.0 kPa (5.8 psi) (0.400 kgf/cm²) Rear: 40.0 kPa (5.8 psi) (0.400 kgf/cm²) · Check and adjust tire pressures when the tires are cold. · Tire pressures must be equal on both sides. G G G Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 37.0 kPa (5.3 psi) (0.370 kgf/cm²) Rear: 37.0 kPa (5.3 psi) (0.370 kgf/cm²) Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (36 psi) (2.5 kgf/cm²) Rear: 250 kPa (36 psi) (2.5 kgf/cm²) Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully. 5 EBU19820 Measuring the tire pressure Use the low-pressure tire gauge. 5-7 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. 5 Recommended pressure: Front 40.0 kPa (5.8 psi) (0.400 kgf/cm²) Rear 40.0 kPa (5.8 psi) (0.400 kgf/cm²) Minimum: Front 37.0 kPa (5.3 psi) (0.370 kgf/cm²) Rear 37.0 kPa (5.3 psi) (0.370 kgf/cm²) Maximum: Front 43.0 kPa (6.2 psi) (0.430 kgf/cm²) Rear 43.0 kPa (6.2 psi) (0.430 kgf/cm²) EBU19830 1. Low-pressure tire gauge Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: 5-8 5 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary. 5-9 EBU19870 OPERATION EWB00010 EBU26532 WARNING Indicates a potential hazard that could result in serious injury or death. EBU19890 Starting a cold engine EWB00620 WARNING POTENTIAL HAZARD Frozen control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding. ECB00150 EWB00610 WARNING 6 POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner's Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer. CAUTION: See the "Engine break-in" section on page 6-5 prior to operating the engine for the first time. 1. Turn the fuel cock to "ON". 2. Turn the main switch to "ON" and the engine stop switch to " ". 6-1 3. Shift the drive select lever into the neutral or park position. The corresponding indicator light should come on, if it does not come on, have a Yamaha dealer check the electrical circuit. NOTE: The engine can be started under the following conditions: G The drive select lever is in the neutral or park position. G The rear brake lever is applied with the drive select lever in any position. However, it is recommended to shift into the neutral or park position before starting the engine. 4. Use the starter (choke) in reference to the figure: Position (1): Cold engine start with ambient temperature below 5 °C (40 °F). Position (2): Cold engine start with ambient temperature between 0 °C (30 °F) and 30 °C (90 °F). Position (3): Cold engine start with ambient temperature above 25 °C (80 °F). 6-2 Ambient temp./starter (choke) position 1. 2. 3. 4. Fully open Half open Closed Starter (choke) 6 5. Apply the rear brake lever. 6. Completely close the throttle lever and start the engine by pushing the start switch. NOTE: 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. 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine. If the engine is started with the starter (choke) in position (2), keep the starter (choke) in this position to warm up the engine. ECB00160 EBU20450 Operating the drive select lever and driving in reverse ECB00170 CAUTION: Before shifting, stop the ATV, otherwise the transmission may be damaged. Shifting: Neutral to Forward 1. Bring the ATV to a complete stop. 2. Apply the brake pedal, and then shift by moving the drive select lever along the shift guide. NOTE: Make sure that the drive select lever is completely shifted into position. CAUTION: For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! 6 8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to position (3) before riding. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. 6-3 3. Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide. 1. 2. 3. 4. 5. Drive select lever F (Forward) N (Neutral) R (Reverse) P (Park) 6 1. 2. 3. 4. 5. Drive select lever F (Forward) N (Neutral) R (Reverse) P (Park) 3. Release the brake pedal, and then open the throttle lever gradually. Shifting: Neutral to Reverse and Reverse to Park NOTE: The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal. 1. Bring the ATV to a complete stop. 2. Apply the brake pedal. 6-4 NOTE: G When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. G Due to the synchronizing mechanism in the engine, the indicator light may not come on until the ATV starts moving. G For ATVs not equipped with an odometer or hour meter, follow the figures given in hours. 4. Check behind for people or obstacles, and then release the brake pedal. 5. Open the throttle lever gradually and continue to watch to the rear while backing. EWB00660 WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or even a person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no people or obstacles behind you. When it is safe to proceed, go slowly. EBU20682 6 There is never a more important period in the life of your engine than the first 320 km (200 mi) or 20 hours of riding. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 320 km (200 mi) or 20 hours. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. 0­160 km (0­100 mi) or 0­10 hours Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position. 160­320 km (100­200 mi) or 10­20 hours Avoid prolonged operation above 3/4 throttle. Rev the engine freely, but do not use full throttle at any time. 320 km (200 mi) or 20 hours and beyond The ATV can now be operated normally. 6-5 Engine break-in NOTE: G For ATVs equipped with an odometer or an hour meter, follow the figures given in km (mi) or the figures given in hours.