Yamaha Grizzly YFM66FAV, Owner'S Manual

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL ...

Page 2: ...EBU00776 ...

Page 3: ...ant 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 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATI...

Page 4: ...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 CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or cleare...

Page 5: ...all applicable OFF ROAD noise level and spark arrester laws and regu lations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU00981 YFM66FAV 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 E_Info fm Page 2 Wednesday J...

Page 6: ...tion number 3 2 Vehicle identification number 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator and warning lights 4 2 Speedometer unit 4 4 Handlebar switches 4 6 Throttle lever 4 13 Speed limiter 4 14 Front brake lever 4 15 Brake pedal and rear brake lever 4 15 Drive select lever 4 16 Recoil starter 4 16 Fuel tank cap 4 17 Fuel cock 4 18 Starter choke 4 19 Seat 4 20 Storage compartment 4 ...

Page 7: ...tarting a cold engine 6 1 Starting a warm engine 6 3 Parking on a slope 6 9 Accessories and loading 6 10 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 3...

Page 8: ...aning 8 34 Spark arrester cleaning 8 38 V belt cooling duct check hose 8 39 Select lever safety system cable adjustment 8 42 Throttle lever adjustment 8 42 Front brake pad check 8 43 Checking the rear brake pads 8 43 Checking the brake fluid level 8 44 Brake fluid replacement 8 46 Front brake lever free play 8 47 Adjusting the rear brake lever and brake pedal 8 48 Adjusting the rear brake light sw...

Page 9: ...ent 8 61 Troubleshooting 8 62 Troubleshooting charts 8 63 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 9 10 11 12 13 EE book Page 4 Thursday March 31 2005 6 57 PM ...

Page 10: ...EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS EE book Page 1 Thursday March 31 2005 6 57 PM ...

Page 11: ...ever 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 85 kg 187 lbs 4WV 24877 A0 LOAD LIMIT PULLING LOAD TONGUE WEIGHT 5390 N 550 kgf 1212 lbf 147 N 15 kgf 33 lbf MAXIMUM LOADING LIMIT 4 WARNING NEVER sit here 3MX 24875 A0 1 2 3 EE book Page 2 Thursday March 31 2005 6 57 PM ...

Page 12: ...5 6 7 EE book Page 3 Thursday March 31 2005 6 57 PM ...

Page 13: ...ate this ATV if you are under age 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death WARNING Turning the ATV in 4WD LOCK DIFF LOCK takes more effort EE book Page 4 Thursday March 31 2005 6 57 PM ...

Page 14: ...hout proper training or instruction Take a Training Course Begin ners 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 Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc Never allow a child under age 16 to operate ...

Page 15: ...erating condition Al ways follow the inspection and maintenance procedures and schedules described in this man ual 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 slip...

Page 16: ...e 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 Alway...

Page 17: ...ded 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 tires specified in this manual Always maintain ...

Page 18: ... of ignition such as the pi lot 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 posi tion 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 gasolin...

Page 19: ...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 EE book Page 6 Thursday March 31 2005 6 57 PM ...

Page 20: ...ng ring 7 Rear brake fluid reservoir 8 Brake pedal 9 V belt case drain plug 10 Radiator cap 11 Drive select lever 15 Fuses 16 Engine oil dipstick 17 Recoil starter 18 Coolant reservoir 19 Drive select lever box check hose 20 V belt cooling duct check hose 21 Rear brake lever 22 Left handlebar switches 23 Starter choke 24 Speedometer unit 25 Main switch 26 Right handlebar switches 27 Throttle lever...

Page 21: ...ng spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EBU00035 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 Key identification number EE book Page 2 Thursday March ...

Page 22: ...ehicle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label EE book Page 3 Thursday March 31 2005 6 57 PM ...

Page 23: ...U00942 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 1 Main switch EE book Page 1 Thursday March 31 2005 6 57 PM ...

Page 24: ...ck indicator light DIFF LOCK This indicator light and the differential gear lock indicator in the display come on when the differential gear lock switch is set to the 4WD LOCK position NOTE _ When the switch is set to LOCK the differ ential gear lock indicator light will flash until the differential gear is locked _ EBU01122 Low range indicator light L This indicator light comes on when the drive ...

Page 25: ... EBU00609 Park indicator light P This indicator light comes on when the drive select lever is in the P park position EBU11312 Four wheel drive indicator This indicator comes on when the 2WD 4WD switch is set to the 4WD position The differential gear lock indicator DIFF LOCK in the four wheel drive indicator also comes on when the LOCK 4WD switch is set to the 4WD LOCK position NOTE _ Due to the sy...

Page 26: ... 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 _ EBU15100 Speedometer unit 1 Speedometer 2 Fuel meter 3 H button 4 M button 5 Clock Hour meter 6 Odometer Tripmeter A Tripmeter B 7 TRIP ODO button 8 Clock Hour button The speedometer...

Page 27: ...ds The tripmeters can be used to estimate the dis tance that can be traveled with a full tank of fu el This information will enable you to plan future fuel stops Clock mode Pushing the button switches the display between the clock mode CLOCK and the hour meter mode HOUR in the fol lowing order CLOCK HOUR CLOCK To set the clock 1 Set the display to the clock mode 2 Push the button until the clock s...

Page 28: ...disappears and the fuel level warning indica tor flashes set the fuel cock to reserve and re fuel as soon as possible 1 Fuel level warning indicator 2 Fuel meter EBU00053 Handlebar switches 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE EBU12040 Light switch OFF Set the switch to to turn on the low beam EE book Page 6 Thursday March 31 2005 6 57 PM ...

Page 29: ...tor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engine See pages 6 1 6 3 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 t...

Page 30: ...s switch to override the 4WD LOCK speed limiting function See pages 4 11 4 12 for a detailed explanation about the differential NOTE _ If the digits of the speedometer appear as shown when the switch is NOT being pushed this could indicate a malfunction in the electri cal system In this case take the ATV to a Yamaha dealer at the first opportunity _ EE book Page 8 Thursday March 31 2005 6 57 PM ...

Page 31: ...D Riding too fast while the ATV is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the ATV The amount of effort is more the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in ...

Page 32: ...from 2WD to 4WD or from 4WD to 4WD LOCK DIFF LOCK or vice versa while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD and in 4WD LOCK in some circumstances Changing from 2WD to 4WD or from 4WD to 4WD LOCK or vice versa while moving may cause the ATV to unexpectedly handle differently This could distract the operator and in crease the risk of losing control and an a...

Page 33: ...the speedometer unit display To change from 4WD to 2WD stop the ATV 1 Differential gear lock switch LOCK 4WD 2 Lever Differential gear lock switch LOCK 4WD To lock the differential gear in 4WD make sure the On Command four wheel drive switch is set to 4WD stop the ATV move the lever to position b and then set the switch to LOCK When the differential gear is locked the differ EE book Page 11 Thursd...

Page 34: ...ited to 35 km h 22 mph However if conditions require full engine power to be available push and hold the override switch to dis able the 4WD LOCK speed limiter See WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the ATV The amount of effort is more the faster you ...

Page 35: ...ing the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver 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 ...

Page 36: ... No more than 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent 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 adjust ed t...

Page 37: ...e front brake lever is located on the right handlebar Pull it toward the handlebar to ap ply the front brake 1 Front brake lever EBU00732 Brake pedal and rear brake lever 1 Brake pedal EE book Page 15 Thursday March 31 2005 6 57 PM ...

Page 38: ...rk positions Refer to pages 6 4 6 6 for the drive select lever operation 1 Drive select lever EBU00855 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt Then pull forcefully being careful not to pull the rope all the way out 1 Recoil starter EE book Page 16 Thursday March 31 2005 6 57 PM ...

Page 39: ...RD Starting the engine without setting the drive select lever to the park position P WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Set the drive select lever to the park po sition before starting the engine EE book Page 17 Thursday March 31 2005 6 57 PM ...

Page 40: ...t 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 1 Arrow mark pointing to OFF OFF Position ON Position EE book Pag...

Page 41: ...ir 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 op eration See pages 6 1 6 3 RES Position EE book Page 19 Thursday March 31 2005 6 57 PM ...

Page 42: ...t the rear 1 Seat 2 Seat lock lever 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 1 Projection 2 2 Seat holder 2 EE book Page 20 Thursday March 31 2005 6 57 PM ...

Page 43: ... s manual or other 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 EBU00582 Front carrier EBU00583 Rear carrier Maximum load limit 45 kg 99 lb Maximum load limit 85 kg 187 lb EE book Page 21 Thursday March 31 2005 6 57 PM ...

Page 44: ...al and installation procedures _ Adjust the spring preload as follows To increase the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring 2 Position indicator NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ Standard position B A Minimum soft E Maximum hard ...

Page 45: ...stment 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 set ting EE book Page 23 Thursday March 31 2005 6 57 PM ...

Page 46: ...The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A EE book Page 24 Thursday March 31 2005 6 57 PM ...

Page 47: ... the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may be come difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged _ EE book Page 25 Thursday March 31 2005 6 57 PM ...

Page 48: ...7 8 15 8 20 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 9 8 25 8 30 Final gear oil Differential gear oil Check for leakage 5 7 5 8 8 21 8 25 Throttle Check for proper throttle cable operation and free play 5 10 8 42 Wheels and tires Check tire pressure wear and damage 5 11 5 14 8 53 8 54 Fittings and fasteners Check all fittings and fasteners 5 10 Lights and...

Page 49: ...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 op erating condition Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual EE book Page 2 Thursday March 31 2005 6 57 PM ...

Page 50: ...be a firm feeling when the brakes are applied If not have a Yamaha dealer inspect the brake system Brake fluid level 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 inspecte...

Page 51: ...ead 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 ad justment procedures provided in this manual have a Yamaha dealer check for the cause EE book Page 4 Thursday March 31 2005 6 57 PM ...

Page 52: ...ng 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 con taining ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gaso hol containing methanol is not recommended by Yamaha because it may cause...

Page 53: ...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 EE book Page 6 Thursday March 31 2005 6...

Page 54: ...tion do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ EBU00493 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 21 8 22 for details 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...

Page 55: ...al gear oil Make sure the differential gear oil is at the specified level Add oil as necessary See pages 8 23 8 25 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil EE book Page 8 Thursday March 31 2005 6 57 PM ...

Page 56: ...o years See pages 8 25 8 30 for details CAUTION _ Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water _ Coolant reservoir capacity WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine 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 t...

Page 57: ...ners 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 Lights Check the headlights and tail brake light to make sure they are in working condition Re EBU11700 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for proper operation EE ...

Page 58: ...model Other tire combina tions are not recommended ACE 01EACE 01E Manufacturer Size Type 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 35 kPa 0 35 kgf cm2 5 0 psi Rear 30 kPa 0 30 kgf cm2 4 3 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire...

Page 59: ...he 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 EE book Page 12 Thursday March 31 2005 6 57 PM ...

Page 60: ...nd 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 specifica tions ACE 02EACE 02E 1 Low pressure tire gauge Recommended pressure Minimum Maximum Front 35 kPa 0 35 kgf cm2 5 0 psi 32 kPa 0 32 kgf cm2 4 6 psi 38 kPa 0 38 kgf cm2 5 4 psi 30 kPa 27 kPa 33 kPa EE book Page 13 Thursday March 31 2005 6 57 PM ...

Page 61: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit EE book Page 14 Thursday March 31 2005 6 57 PM ...

Page 62: ...th 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 WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW TO AV...

Page 63: ...utral or park before starting the engine _ 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warming up position Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 6...

Page 64: ...ne If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it CAUTION _ See the Engine break in section prior to operating the engine for the first time _ EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used Th...

Page 65: ..._ Shifting Neutral to High and High to Low 1 Bring the ATV to a complete stop and re turn the throttle lever to the closed posi tion 2 Apply the brakes then shift by moving the drive select lever along the shift guide NOTE _ Make sure that the drive select lever is com pletely shifted into position 1 Drive select lever 3 Open the throttle lever gradually EE book Page 4 Thursday March 31 2005 6 57 ...

Page 66: ...he brake pedal 3 Shift from neutral to reverse or from re verse to park and vice versa by moving the drive select lever along the shift guide 1 Drive select lever NOTE _ When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the electrical circuit Due to the synchronizing mechanism in the engine the light may not come on un til the ATV...

Page 67: ...mproperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slow ly EE book Page 6 Thursday March 31 2005 6 57 PM ...

Page 68: ...ich might result in ex cessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this ...

Page 69: ...full throttle at any time After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00612 Parking When parking stop the engine and shift the drive select lever into the park position then turn the fuel cock to the OFF position EE book Page 8 Thursday March 31 2005 6 57 PM ...

Page 70: ...AN HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the machine transversely across the in cline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them ea...

Page 71: ... a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object att...

Page 72: ...carrying cargo and towing a trail er include the tongue weight in the maxi mum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can ca...

Page 73: ...oid hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed...

Page 74: ...EBU15122 WARNING _ Indicates a potential hazard that could result in serious injury or death EE book Page 13 Thursday March 31 2005 6 57 PM ...

Page 75: ...7 1 Riding Your ATV EE book Page 1 Thursday March 31 2005 6 57 PM ...

Page 76: ...ction however are appropriate for all types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers begin to ride be sure you have read this Own er s Manual completely and understand the operation of the controls Pay particular atten tion to the safety information ...

Page 77: ... of time Take the time to learn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills...

Page 78: ...commenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc EE book Page 5 Thursday March 31 2005 6 57 PM ...

Page 79: ...PEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers EE book Page 6 Thursday March 31 2005 6 57 PM ...

Page 80: ...n accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sle...

Page 81: ...ZARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV EE book Page 8 Thursday March 31 2005 6 57 PM ...

Page 82: ...afe op erating condition Always follow the in spection and maintenance procedures WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use...

Page 83: ...r is pushed to the maxi mum Screwing in the adjuster limits the max imum engine power available and decreases the maximum speed of the ATV Turning the screw in decreases top speed and turning it out increases top speed WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV which can resul...

Page 84: ...iler hitch Pulling load 550 kgf 1 212 lbf Total weight of trailer and cargo Tongue weight 15 kgf 33 lbf WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and secur...

Page 85: ... even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation ...

Page 86: ...NG POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off EE book Page 13 Thursday March 31 2005 6 57 PM ...

Page 87: ... cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed EE book Page 14 Thursday March 31 2005 6 57 PM ...

Page 88: ...t WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it EE book Page 15 Thursday M...

Page 89: ...g this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets EE book Page 16 Thursday March 31 2005 6 57 PM ...

Page 90: ...perating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways EE book Page 17 Thursday March 31 2005 6 57 PM ...

Page 91: ...OTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturn ing or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar terrain Always be EE book Page 18 Thursday March 31 2005 6 57 PM ...

Page 92: ... or vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain EE book Page 19 Thursday March 31 2005 6 57 PM ...

Page 93: ...iler hitch Do not ride in areas posted no trespassing Do not ride on private property without getting permission WARNING WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles EE book Page 20 Thursday March 31 2005 6 57 PM ...

Page 94: ...hen riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling shift the drive select le ver to the low position L or the high position H Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a lo...

Page 95: ...e slow down and be gin to turn the handlebars in the desired direc tion As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a HOW TO AVOID THE HAZARD Always follow proper procedures f...

Page 96: ...Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember ...

Page 97: ...ortant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small...

Page 98: ...s as described in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards An obstacle a sharp drop or another vehicle or person could be on the other side of the hill EE book Page 25 Thursday March 31 2005 6 57 PM ...

Page 99: ...OTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible EE...

Page 100: ... a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV EE book Page 27 Thursday March 31 2005 6 57 PM ...

Page 101: ...d by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake ped al will brake the wheels on the downhill side the front and rear brakes gradually or dis mount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing...

Page 102: ...nt brake 4WD or 4WD LOCK Apply both front and rear brakes gradually When fully stopped shift to the park ing position P Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu al EE book Page 29 Thursday March 31 2005 6 57 PM ...

Page 103: ...ay also cause a loss of traction When this ATV is in 4WD or 4WD LOCK all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden application of either the front or rear brake be cause th...

Page 104: ...o ing down hills as described in this Own er s Manual Note a special technique is required when braking as you go down a hill HOW TO AVOID THE HAZARD Always check the terrain carefully be fore 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 EE book Page 31 Thursday March 31 2005 6 57 PM ...

Page 105: ...tly up hill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill u...

Page 106: ...EE book Page 33 Thursday March 31 2005 6 57 PM ...

Page 107: ...pery or up set the ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to ...

Page 108: ...to drain the trapped water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose and the drive select lever box check hose Also remove the V belt case drain plug to drain any water that may have accumulat ed Wash the ATV in fresh water if it has been operated in salt water or muddy con ditions _ EE book Page 35 Thursday March 31 2005 6 57 PM ...

Page 109: ...1 V belt cooling duct check hose Left side 1 Drive select lever box check hose EE book Page 36 Thursday March 31 2005 6 57 PM ...

Page 110: ...trol and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper proce...

Page 111: ... wheels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide EE book Page 38 Thursday March 31 200...

Page 112: ...control may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautiou...

Page 113: ...e If necessary gradually let off the throttle and or steer to the outside of the turn See If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerat ing is not recommended until you have cor rected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for wa...

Page 114: ... cover that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV un til you have regained adequate braking ability S...

Page 115: ... manual and tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it in the storage box Put the owner s tool kit and low pressure tire gauge in the space beside the battery WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or ...

Page 116: ... your machine to a Yamaha dealer to check the torque settings and adjust them as neces sary _ WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er in...

Page 117: ...n asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills _ ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 300 800 2 500 1 600 2 500 1 600 5 000 3 200 hours 20 80 160 160 320 Fuel line Check fuel hose for cracks or damage Replace if necessary Valves Check valve clearance Adjust if necessary Spark plug Check conditio...

Page 118: ...al gear oil Check oil level oil leakage Replace Differential gear oil Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months Front brake Check operation fluid leakage see NOTE page 8 5 Correct if necessary Rear brake Check operation fluid leakage see NOTE page 8 5 Correct if necessary Select lever safety system cable Check operation Adjust if necessary V belt Chec...

Page 119: ...with lithium soap based grease Engine mount Check for cracks or damage Front and rear axle boots Check operation Replace if damaged Stabilizer bushes Check for cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check operation Adjust headlight beam ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 ...

Page 120: ...ed to be removed to perform some of the maintenance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 1 Panel A 2 Panel B 3 Panel C 1 Panel D 2 Panel E 3 Panel F 4 Panel G EE book Page 6 Thursday March 31 2005 6 57 PM ...

Page 121: ...nd D To remove 1 Remove the seat See page 4 20 for seat removal and installation proce dures 2 Pull outward on the area shown and then pull upward as shown 1 Panel A 1 Panel D EE book Page 7 Thursday March 31 2005 6 57 PM ...

Page 122: ...all 1 Insert the panel projections in the numer ical order shown in the illustration and then push inward on the area shown 2 Install the seat 1 Panel A 1 Panel D EE book Page 8 Thursday March 31 2005 6 57 PM ...

Page 123: ...ove the bolts To install Place the panel in the original position and in stall the bolts 1 Panel B 2 Bolt 2 CAUTION _ When installing the panel be sure not to pinch the cables or wires _ EE book Page 9 Thursday March 31 2005 6 57 PM ...

Page 124: ...1141 Panel C To remove 1 Remove the front carrier by removing the stay covers at the rear then by removing the bolts 1 Front carrier stay cover 2 1 Bolt 2 top EE book Page 10 Thursday March 31 2005 6 57 PM ...

Page 125: ...position and install the quick fasteners 2 Install the front carrier by installing the bolts and tightening them to the specified torques 3 Install the stay covers Tightening torques Carrier bolt top 26 Nm 2 6 m kgf 19 ft lbf Carrier bolt under fenders 7 Nm 0 7 m kgf 5 1 ft lbf EE book Page 11 Thursday March 31 2005 6 57 PM ...

Page 126: ...3 Panel E To remove Remove the bolts and then take the panel off To install Place the panel in the original position and then install the bolts 1 Panel E 2 Bolt 6 EE book Page 12 Thursday March 31 2005 6 57 PM ...

Page 127: ...EBU00638 Panel F To remove Pull outward on the areas shown 1 Panel F To install Place the panel in its original position EE book Page 13 Thursday March 31 2005 6 57 PM ...

Page 128: ...age 4 20 for seat removal and installation proce dures 2 Remove the rear carrier by removing the bolts 1 Bolt 4 top 1 Bolt 2 under fenders 3 Remove the seat under bracket and the panel by pulling them off EE book Page 14 Thursday March 31 2005 6 57 PM ...

Page 129: ...and the oil filter cartridge replaced at the inter vals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Remove panel F See page 8 13 for panel removal and installation proce dures 2 Place the ATV on a level surface 3 Start the engine warm it up for several minutes and then turn it off 4 Wait a few minutes until the oil settles Tightening torques Carrier ...

Page 130: ... cap 2 Dipstick 6 Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level NOTE _ The engine oil should be between the mini mum and maximum level marks _ 1 Maximum level mark 2 Minimum level mark EE book Page 16 Thursday March 31 2005 6 57 PM ...

Page 131: ... change the engine oil with or without oil filter cartridge replacement 1 Remove panel F See page 8 13 for panel removal and installation proce dures 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to col lect the used oil and then remove the en gine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase EE b...

Page 132: ...8 7 8 8 and 8 12 for panel remov al and installation procedures 6 Remove the oil filter cartridge with an oil filter wrench 7 Apply a light coat of engine oil to the O ring of the new oil filter cartridge NOTE _ Make sure the O ring is seated properly _ 1 O ring EE book Page 18 Thursday March 31 2005 6 57 PM ...

Page 133: ...pecified amount of recommend ed engine oil and then install the engine oil filler cap and tighten it Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 1 9 L 1 67 Imp qt 2 01 US qt With oil filter cartridge replacement 2 0 L 1 76...

Page 134: ...y than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ 12 Start the engine and warm it up for seve ral minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 13 Turn the engine off and then check the EE book Page 20 Thursday March 31 2005 6...

Page 135: ... on a level surface 2 Place a container under the final gear case to collect the used oil 3 Remove the oil filler bolt and the drain bolt to drain the oil 1 Final gear oil drain bolt 4 Install the drain bolt and tighten it to the specified torque 5 Fill the final gear case with the specified Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf EE book Page 21 Thursday March 31 200...

Page 136: ...n it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf EE book Page 22 Thursday March 31 2005 6 57 PM ...

Page 137: ...le If the level is low add sufficient oil of the recommend ed type to raise it to the specified level 1 Differential gear oil CAUTION _ Be sure no foreign material enters the dif ferential gear case _ 3 Install the differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf EE book Page 23 Thursday Marc...

Page 138: ...tial gear oil drain bolt 4 Install the differential gear oil drain bolt and tighten it to the specified torque 5 Fill the differential gear case with the rec ommended oil CAUTION _ Be sure no foreign material enters the dif ferential gear case _ Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 28 L 0 25 Imp...

Page 139: ... Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine tem perature NOTE _ The coolant should be between the minimum and maximum level marks _ Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf EE book Page 25 Thursday March 31 2005 6 57 PM ...

Page 140: ... to the engine You may use soft water if you can not get distilled water _ NOTE _ If water is added have a Yamaha dealer check the antifreeze content of the cool ant as soon as possible The radiator fan operation is completely automatic It is switched on or off accord ing to the coolant temperature in the radi ator _ If your ATV overheats see page 8 64 for de tails Coolant reservoir capacity up to...

Page 141: ... to prevent coolant from spilling on the foot rest WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine 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 re moving the radiator cap Always use a thick rag over the cap Allow any re maining pressure to escape before c...

Page 142: ... 1 Radiator cap 5 Remove the radiator cap 6 Remove panel D See pages 8 7 8 8 for panel removal and installation proce dures 7 Remove the coolant reservoir cap 8 Disconnect the hose on the coolant res ervoir side and then drain the coolant from the coolant reservoir EE book Page 28 Thursday March 31 2005 6 57 PM ...

Page 143: ... reservoir to the maximum level mark and then install the reservoir cap and panel D 13 Pour the recommended coolant into the radiator until it is full and then install the radiator cap Tightening torque Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze and water mixing ratio 1 1 Total amount 1 8 L 1 58 Imp qt 1 90 US qt C...

Page 144: ... for several minutes Stop the engine and then check the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator 15 Check for coolant leakage NOTE _ If any leakage is found have a Yamaha deal er check the cooling system _ 16 Install the panels and the front carrier EE book Page 30 Thursday March 31 2005 6 57 PM ...

Page 145: ...oots Check the protective boots for holes or tears If any damage is found have them replaced by a Yamaha dealer 1 Front axle boot 2 each side 1 Rear axle boot 2 each side EE book Page 31 Thursday March 31 2005 6 57 PM ...

Page 146: ...l 1 Remove panel A See pages 8 7 8 8 for panel removal and installation proce dures 2 Remove the spark plug cap 1 Spark plug cap 3 Use the spark plug wrench in the tool kit 1 Spark plug wrench EE book Page 32 Thursday March 31 2005 6 57 PM ...

Page 147: ...TV to a Yamaha dealer You should periodically re move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should re place the spark plug with the specified plug Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust...

Page 148: ...4 Install the spark plug cap 5 Install the panel EBU12111 Air filter element cleaning NOTE _ There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seat See page 4 20 for Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf EE book Page 3...

Page 149: ...1 Holder 5 2 Air filter case cover 3 Remove the air filter element 4 Remove the air filter element from its frame EE book Page 35 Thursday March 31 2005 6 57 PM ...

Page 150: ... foam air filter oil to the air filter el ement NOTE _ The air filter element should be wet but not dripping _ 9 Pull the air filter element over its frame 10 Install the air filter element WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use pa...

Page 151: ...ions Check the air filter element rubber joint to the carburetor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine _ CAUTION _ Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration without t...

Page 152: ...pe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install and tighten the bolts 1 Bolt 3 EE book Page 38 Thursday March 31 2005 6 57 PM ...

Page 153: ...ng of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool pri or to touching exhaust components Do not start the engine when cleaning the exhaust system EE book Page 39 Thursday Marc...

Page 154: ...he carburetor is a vital part of the engine and requires very sophisticated adjustment Most adjusting should be left to a Yamaha dealer who has the professional knowledge and ex perience to do so However the idling speed may be performed by the owner as a part of the usual maintenance routine CAUTION The carburetor was set at the Yamaha fac tory after many tests If the settings are disturbed by so...

Page 155: ...emoval and installation procedures 3 Connect the tachometer to the spark plug lead and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction a to increase the engine speed and in direc 1 Throttle stop screw 4 Install the panel EBU00303 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air su...

Page 156: ...be adjusted regu larly This adjustment however should be left to a Yamaha dealer EBU00307 Throttle lever adjustment NOTE Adjust the engine idling speed before adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle le ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut EE book Page 42 Thursday March 31 2005 6 57 PM ...

Page 157: ...pads as a set 1 Brake pad a Brake pad thickness NOTE _ The wheels need to be removed to check the EBU08781 Checking the rear brake pads Check the brake pads for damage and wear If the thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the pads 1 Brake pad 2 Brake pad plate a Brake pad thickness EE book Page 43 Thursday March 31 2005 6 57 PM ...

Page 158: ...replenish when necessary A low brake fluid level may indi cate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage The rear brake fluid master cylinder reservoir is located behind panel B See page 8 9 for panel removal and installation procedures 1 Minimum level mark FRONT REAR EE book Page 44 Thursda...

Page 159: ...ds may result in a harmful chemical reaction and lead to poor brake perfor mance Be careful that water does not enter the master cylinder reservoirs when refilling Water will significantly lower the boiling point of the fluid and may result in vapor Brake fluid may deteriorate painted surfac es or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer check the cause if the b...

Page 160: ... by trained Yamaha service personnel Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years EE book Page 46 Thursday March 31 2005 6 57 PM ...

Page 161: ...ting with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re EE book Page ...

Page 162: ...ke lever free play 2 Turn the adjusting bolt in direction a to increase free play and in direction b to decrease free play 3 Tighten the locknut If correct free play cannot be obtained ask a Yamaha dealer to make that adjustment NOTE _ When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move _ EE book Page 48 Thursday March 31 200...

Page 163: ...ting with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag All air must be bled from the brake system Replacement of brake components re quires professional knowledge These EE book Page ...

Page 164: ...rake light switch as follows 1 Remove panel B See page 8 9 for pan el removal and installation procedures 2 Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjust ing nut in direction b 1 Rear brake light switch 2 Adjusting nut 3 Install the panel E...

Page 165: ...ge 8 9 for panel removal and installation procedures _ WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Recomm...

Page 166: ...upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun 1 Upper knuckle 2 Lower knuckle Recommended lubricant Lithium soap based grease EE book Page 52 Thursday March 31 2005 6 57 PM ...

Page 167: ...l 4 Remove the wheel 1 Nut 4 EBU11211 Wheel installation 1 Install the wheel and the nuts NOTE _ The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its ta pered side towards the wheel _ EE book Page 53 Thursday March 31 2005 6 57 PM ...

Page 168: ...er the ATV so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf EE book Page 54 Thursday March 31 2005 6 57 PM ...

Page 169: ...T CAN HAPPEN You could be poisoned You could be HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes...

Page 170: ...ry Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU08762 Fuse replacement 1 The main fuse and the fuse box are locat ed under the seat 2 If a fuse is blown turn off the main switch and the switch of the circuit in question Then install a new fuse of the specified amperage Turn on the ma...

Page 171: ...urn off the main switch when checking or replacing a fuse _ Specified fuses Main fuse 30A Headlight fuse 15A Ignition fuse 10A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse EE book...

Page 172: ...Remove the cover at the rear of the headlight by pulling it off 1 Cover 2 Remove the headlight bulb holder cover by pulling it off 1 Headlight bulb holder cover 3 Remove the headlight bulb holder by push ing it in and turning it counterclockwise EE book Page 58 Thursday March 31 2005 6 57 PM ...

Page 173: ...b life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner _ WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to co...

Page 174: ...b holder cover and the cov er at the rear of the headlight EBU01089 Headlight beam adjustment CAUTION _ It is advisable to have a Yamaha dealer make this adjustment _ To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b EE book Page 60 Thursday March 31 2005 6 57 PM ...

Page 175: ...dures 2 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Tail brake light bulb holder 3 Remove the defective bulb from the bulb holder by pushing it inward and turning it 5 Install the bulb holder together with the bulb 6 Install the panel EE book Page 61 Thursday March 31 2005 6 57 PM ...

Page 176: ...erience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se ve...

Page 177: ...ompression Use the electric starter to see if there is compression There is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Check the fuel flow Turn the fue...

Page 178: ...g over the cap Al low any remaining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See NOTE Restart the engine If the engine overheats again ask...

Page 179: ...axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash ers 4 Once the ...

Page 180: ...ch may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out th...

Page 181: ...tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing in a humid or salt ...

Page 182: ... dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine EE book Page 4 Thursday March 31 2005 6 57 PM ...

Page 183: ... 34 6 in Wheelbase 1 275 mm 50 2 in Ground clearance 275 mm 10 8 in Minimum turning radius 3 200 mm 126 0 in Basic weight With oil and full fuel tank 290 kg 639 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 660 cm3 Bore stroke 100 84 mm 3 94 3 31 in EE book Page 1 Thursday March 31 2005 6 57 PM ...

Page 184: ...r higher Quantity Without oil filter cartridge replacement 1 9 L 1 67 Imp qt 2 01 US qt Model YFM66FA CAUTION In order to prevent clutch slippage since the en gine 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 EE book Pag...

Page 185: ...city including all routes 1 80 L 1 58 Imp qt 1 90 US qt Air filter Wet type element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 20 L 4 40 lmp gal 5 28 US gal Fuel reserve amount 3 5 L 0 77 lmp gal 0 92 US gal Carburetor Type quantity BSR42 1 Manufacturer MIKUNI Spark plug Type manufacturer DPR8EA 9 NGK Spark plug gap 0 8 0 9 mm 0 031 0 035 in Model YFM66FA EE book Page 3 Thursday March 31 ...

Page 186: ... Transmission type V belt automatic Operation Left hand operation Reverse gear 25 17 1 471 Sub transmission ratio low 35 17 2 058 high 26 21 1 238 Chassis Frame type Steel tube frame Caster angle 5 Trail 26 mm 1 02 in Tire Type Tubeless Size front AT25 8 12 rear AT25 10 12 Model YFM66FA EE book Page 4 Thursday March 31 2005 6 57 PM ...

Page 187: ... Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 170 mm 6 69 in Rear wheel travel 225 mm 8 86 in Electrical Ignition system DC C D I Generator system A C magneto Battery type YTX20L BS Model YFM66FA EE book Page 5 Thursday March 31 2005 6 57 PM ...

Page 188: ... Coolant temperature warning light LED Park indicator light LED High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Fuses Main fuse 30A Headlight fuse 15A Ignition fuse 10A Auxiliary DC jack fuse 10A Four wheel drive fuse 3A Signaling system fuse 10A Model YFM66FA EE book Page 6 Thursday March 31 2005 6 57 PM ...

Page 189: ...pose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Mu...

Page 190: ...re minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 07E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 300 800 80 6 2 500 1 600 160 12 5 000 3 200 320 18 7 500 4 800 480 24 10 000 6 400 640 30 12 500 8 000 800 36 15 000 9 600 960 42 17 500 11 200 1 120 48 20 000 12 800 1...

Page 191: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY E 13 fm Page 1 Wednesday June 29 2005 10 16 AM ...

Page 192: ...1 2 3 4 5 6 7 8 9 10 11 12 13 EE book Page 2 Thursday March 31 2005 6 57 PM ...

Page 193: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S EE book Page 1 Thursday March 31 2005 6 57 PM ...

Page 194: ...1 2 3 4 5 6 7 8 9 10 11 12 13 EE book Page 2 Thursday March 31 2005 6 57 PM ...

Page 195: ...EBU00437 EE book Page 3 Thursday March 31 2005 6 57 PM ...

Page 196: ...ct handling and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PU...

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