Yamaha KODIAK 700 YFM70KDXH, Owner'S Manual

Page 1: ... PROPRIÉTAIRE MANUAL DEL PROPIETARIO B16 F8199 61 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad ...

Page 2: ...DIC183 Original instructions Notice originale Manual original PRINTED IN USA 2016 06 0 3 1 CR E F S ...

Page 3: ...tains important safety information WARNING OWNER S MANUAL YFM70KDXH YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH This ATV should not be ridden by anyone under 16 years of age B16 F8199 61 E0 UB1661E0 book Page 1 Thursday May 12 2016 2 47 PM ...

Page 4: ...OPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted ...

Page 5: ... Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title and or number and date of issue of standards and or specifications Authorized Repre...

Page 6: ...sic understanding of the features and operation of this ATV This manual includes important safety information It provides information about special techni ques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read ...

Page 7: ... safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key info...

Page 8: ...ease check your local riding laws and regulations before operating this ATV EBU17411 YFM70KDXH YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH OWNER S MANUAL 2016 by Yamaha Motor Co Ltd 1st edition March 2016 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A UB1661E0 book Page 1 Thursday May 12 2016 2 47 PM...

Page 9: ...PHH YFM70KPAH 4 15 Throttle lever 4 16 Speed limiter 4 17 Front brake lever 4 18 Brake pedal and rear brake lever 4 18 Drive select lever 4 19 Fuel tank cap 4 19 Fuel 4 19 Seat 4 21 Storage compartment 4 22 Front carrier 4 23 Rear carrier 4 23 Adjusting the front and rear shock absorber assemblies YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH 4 24 Trailer hitch YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH 4 ...

Page 10: ...O IF 7 22 WHAT TO DO 7 22 PERIODIC MAINTENANCE AND ADJUSTMENT 8 1 Owner s manual and tool kit 8 2 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing panels 8 9 Checking the spark plug 8 17 Engine oil and oil filter cartridge 8 20 Final gear oil 8 24 Differential gear oil 8 27 Coolant 8 29 Cleaning the air filter elem...

Page 11: ...zer bushes 8 51 Lubricating the rear knuckle pivots 8 52 Lubricating the steering shaft 8 52 Battery 8 53 Replacing a fuse 8 57 Replacing a headlight bulb 8 59 Adjusting a headlight beam 8 62 Replacing the tail brake light bulb 8 63 Removing a wheel 8 64 Installing a wheel 8 64 Troubleshooting 8 65 Troubleshooting charts 8 66 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CO...

Page 12: ... all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a re placement label from your Yamaha dealer UB1661E0 book Page 1 Thursday May 12 2016 2 47 PM ...

Page 13: ...1 2 1 For Europe 1 2 3 4 5 10 8 9 7 6 UB1661E0 book Page 2 Thursday May 12 2016 2 47 PM ...

Page 14: ...15 kgf 33 lbf 37S F817S 00 B16 F817R 10 90 kg 198 lbs 35 0 kPa 0 35 kgf cm 5 0 psi 30 0 kPa 0 30 kgf cm 4 4 psi 1HP F816M M0 YAMAHA B16 F817R 00 50 kg 110 lbs 1P0 F816P 20 YAMAHA 1 2 3 4 5 UB1661E0 book Page 3 Thursday May 12 2016 2 47 PM ...

Page 15: ...AMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWBD 36 0 kW 307 kg 2016 2SM F155A 10 YAMAHA 1HP F811R 00 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWBD 36 0 kW 312 kg 2016 B32 F155A 10 6 YFM70KDXH 6 YFM70KPXH YFM70KPHH 6 YFM70KPSH 7 8 UB1661E0 book Page 4 Thursday May 12 2016 2 47 PM ...

Page 16: ...1 5 1 1P0 F816R 00 YAMAHA B16 F816N 01 4 kg 9 lb 9 10 UB1661E0 book Page 5 Thursday May 12 2016 2 47 PM ...

Page 17: ... from 12 years old Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 16 Use from 16 years old Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER use on paved roads NEVER carry passengers NEVER use with drugs or alcohol NEVER store fuel or flammable...

Page 18: ...loss of control Adjust the tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all other load rel...

Page 19: ...1 8 1 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN kW kg 1 2 3 4 1 2 3 4 Year of construction Model Name Max Power Mass In Running Order UB1661E0 book Page 8 Thursday May 12 2016 2 47 PM ...

Page 20: ...1 9 1 For Oceania 3 5 4 9 6 7 8 1 2 UB1661E0 book Page 9 Thursday May 12 2016 2 47 PM ...

Page 21: ...0 YAMAHA MAXIMUM LOADING LIMIT 37S F151K 00 PULLING LOAD 5880 N 600 kgf 1322 lbf TONGUE WEIGHT 147 N 15 kgf 33 lbf YAMAHA WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 1 2 3 4 UB1661E0 book Page 10 Thursday May 12 2016 2 47 PM ...

Page 22: ... 240 kg 530 lbs Includes weight of operator cargo and accessories and if applicable trailer tongue weight WARNING B16 F816M 00 YAMAHA IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold LOADING TRAILER TOWING WARNING NEVER operate this ATV if you are under age 16 Operating this ATV if you a...

Page 23: ...on 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 use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S M...

Page 24: ...ild under 16 years old should never oper ate an ATV with engine size greater than 90 cc 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 This vehicle is intended for off road use only Do not operate on any paved surfaces such...

Page 25: ...ting 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 Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shif...

Page 26: ...h as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there ar...

Page 27: ...ssary If you can physically operate your vehicle inspect your vehicle If the vehicle is in safe operating con dition and you can safely operate it restart it and ride gently back to camp or other known location where you can receive medical at tention If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If yo...

Page 28: ... the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries re lated to changes in the vehicle Keep the following guidelines in mind as well as those provided un der Loading when mounting accessories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before...

Page 29: ...o deadly levels of carbon monoxide can linger for hours or days in en closed or poorly ventilated areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run...

Page 30: ...olant reservoir 5 1 2 3 4 7 8 6 9 1 Rear shock absorber assembly spring preload adjusting ring YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH 2 Fuel tank cap 3 Owner s tool kit 4 Storage compartment 5 Spark plug 6 Front shock absorber assembly spring preload adjusting ring YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH 7 Brake pedal 8 V belt case drain plug 5 1 6 2 3 4 7 8 UB1661E0 book Page 1 Thursday May 12 2...

Page 31: ...rottle lever 10 Auxiliary DC jack 11 Main switch 1 2 3 4 5 6 7 8 9 1011 1 Drive select lever 2 Rear brake lever 3 Handlebar switches 4 Horn switch 5 Drive lever 2WD 4WD YFM70KPXH YFM70KPHH YFM70KPAH 6 Multi function display 7 Front brake fluid reservoir 8 On Command four wheel drive differential gear lock switch YFM70KPSH 9 Front brake lever 10 Throttle lever 11 Auxiliary DC jack 12 Main switch 1 ...

Page 32: ...3 3 3 TIP The ATV you have purchased may differ slightly from the figures shown in this manual UB1661E0 book Page 3 Thursday May 12 2016 2 47 PM ...

Page 33: ... 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 re moved 1 Main switch 1 UB1661E0 book Page 1 Thursday May 12 2016 2 47 PM ...

Page 34: ... light 1 2 3 4 5 6 7 1 On Command differential gear lock indicator light DIFF LOCK YFM70KPSH 2 Low range indicator light L 3 High range indicator light H 4 Neutral indicator light N 5 Reverse indicator light R 6 Park indicator light P 7 Four wheel drive indicator 8 On Command differential gear lock indicator YFM70KPSH 9 Engine trouble warning light 10 Coolant temperature warning light 11 Electric ...

Page 35: ...U34560 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 The electrical circuit of the warning light can be checked by turning the key to on The warning light should come on for a few seconds and then go off If the warning light does ...

Page 36: ...ectrical circuit EBU27287 Engine trouble warning light YFM70KDXH This warning light comes on or flashes when an electrical circuit monitoring the engine is not work ing correctly When this occurs have a Yamaha dealer check the self diagnosis system YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine...

Page 37: ...icate that the power assistance for the steering is not functioning If the steering load is too heavy i e excessive steering use when the ATV is traveling at a slow speed the power assist is reduced to protect the EPS motor from overheating EBU34250 Four wheel drive indicator light YFM70KDXH This indicator light comes on when the drive lever is set to the 4WD position TIP Due to the synchronizing ...

Page 38: ...ear is completely locked or unlocked If the indicator and the indica tor light continue to flash the differential is not completely locked or unlocked In this case start moving to allow time for the differential to lock or unlock EBU30498 Multi function display YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH The multi function display is equipped with the following speedometer odometer 1 SELECT button 2 R...

Page 39: ...mate the distance that can be traveled with a full tank of gas etc Push the SELECT button to switch between the odometer ODO and the tripmeters TRIP A and TRIP B in the following order ODO TRIP A TRIP B ODO To reset a tripmeter set the display to the tripme ter you want to reset then push the RESET but ton for three seconds TIP The odometer will lock at 99999 The tripmeters will reset and continue...

Page 40: ...isappear from F full towards E empty as the fuel level decreases When the E segment disappears and the fuel level warning indicator flashes refuel as soon as possible TIP The fuel gauge is equipped with a self diagnosis system If the fuel gauge electrical circuit is not working correctly all display segments and the fuel level warning indicator will flash repeatedly If this occurs have a Yamaha de...

Page 41: ...es an error code note the code number and have a Yamaha dealer check the vehicle NOTICE ECB00812 If the multi function display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage EBU18066 Handlebar switches YFM70KDXH YFM70KPXH YFM70KPHH YFM70KPAH 1 Error code display 2 Engine trouble warning light 1 2 1 Light switch OFF 2 Engine stop switch 3 S...

Page 42: ...adlights low beams and the taillight Set the switch to to turn on the left and right head lights high beams the handlebar mounted light YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00044 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to the point that th...

Page 43: ...l appear as shown in the figure TIP If the digits of the speedometer appear as shown when the switch is NOT being pushed this could indicate a malfunction in the electrical system In this case take the ATV to a Yamaha dealer at the first opportunity WARNING EWB00151 Always ride at a slow speed when the ATV is in four wheel drive differential gear lock and al low extra time and distance for maneuve...

Page 44: ...r ator and increase the risk of losing control and of causing an accident This ATV is equipped with a switch to change from two wheel drive to four wheel drive and vice ver sa Select the appropriate drive according to the terrain and the conditions 2WD two wheel drive Power is supplied to the rear wheels 4WD four wheel drive Power is supplied to the rear and front wheels To change from two wheel d...

Page 45: ...and allow extra time and distance for maneuvers All wheels turn at the same speed when the dif ferential gear is locked so it takes more effort to turn the ATV The effort needed to turn in creases with the riding speed You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling This ATV is equipped with a switch allowing you to lock the differen...

Page 46: ...ock switch in to the LOCK position When the differential gear is locked the differential gear lock indicator light DIFF LOCK will come on along with the indicator in the multi function dis play 1 On Command four wheel drive switch 2WD 4WD 2 On Command differential gear lock switch 4WD LOCK 2WD 4WD 1 2 1 Differential gear lock lever 2 On Command four wheel drive switch 2WD 4WD 2WD 4WD 2 1 a UB1661E...

Page 47: ...or disengaged When the ATV is in four wheel drive differential gear lock the maximum traveling speed is limit ed to 35 km h 22 mi h However if conditions require full engine power to be available push and hold the override switch to disable the dif ferential gear lock speed limiter See page 4 11 for a detailed explanation of this switch EBU34130 Drive lever 2WD 4WD YFM70KDXH YFM70KPXH YFM70KPHH YF...

Page 48: ...nd set the lever to the 4WD position Then the four wheel drive indi cator light YFM70KDXH or the four wheel drive indicator YFM70KPXH YFM70KPHH YFM70KPAH comes on To change from four wheel drive to two wheel drive stop the vehicle and set the lever to the 2WD position EBU18283 Throttle lever Once the engine is running pushing the throttle le ver will increase the engine speed Regulate the speed of...

Page 49: ...ng screw in direction a To decrease the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction b Do not turn the adjusting screw out more than 12 mm 0 47 in or the throttle cable could be damaged Always make sure the throttle lever free play is adjusted to 3 0 5 0 mm 0 12 0 20 in See page 8 41 WARNING Im proper adjustment of the speed limiter and thr...

Page 50: ...lebar grip EBU18443 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 1 Front brake lever 1 Brake pedal 1 Rear brake lever 1 1 UB1661E0 book Page 18 Thursday May 12 2016 2 47 PM ...

Page 51: ...nk cap by turning it counter clockwise EBU18757 Fuel Make sure there is sufficient gasoline in the tank WARNING EWB02522 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling fol low these instructions 1 Before refueling turn off the engine and be sure that no one is sitting on the vehicle Nev er refuel while smoking or w...

Page 52: ...e fuel may deteriorate painted surfaces or plastic parts ECB00982 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed WARNING EWB02532 Gasoline is poisonous and can cause injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor 1 Fuel tank ...

Page 53: ... regular unleaded gasoline with a research octane number of 91 or higher 95 or higher for Europe If knocking or pinging occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce maintenance costs EBU34140 Seat To remove the seat Pull up the seat at the rear and then pull the seat rearward To install the seat Insert the projections on the front of the se...

Page 54: ...tored wrap them in appropriate cushion material to prevent damaging the stor age compartment The storage compartment is located in front of the seat To access the storage compartment open the storage compartment lid 1 Projection 2 Seat holder 1 1 2 2 1 Storage compartment lid 1 Storage compartment 1 1 UB1661E0 book Page 22 Thursday May 12 2016 2 47 PM ...

Page 55: ...n plug is fitted at the bottom of the storage compartment If any water collects in the storage compartment remove the drain plug drain the water and then install the drain plug EBU18963 Front carrier Do not exceed the load limit of 50 0 kg 110 lb for the front carrier Do not exceed the maximum load of 240 0 kg 530 lb for the ATV EBU18973 Rear carrier Do not exceed the load limit of 90 0 kg 198 lb ...

Page 56: ...tability which could lead to an ac cident Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber TIP A special wre...

Page 57: ...t can be obtained at a Yamaha dealer See page 6 6 for precaution in formation 1 Special wrench Spring preload setting Minimum soft 1 YFM70KPAH YFM70KPHH YFM70KPSH YFM70KPXH Standard 2 YFM70KPAH YFM70KPHH YFM70KPSH YFM70KPXH Maximum hard 5 YFM70KPAH YFM70KPHH YFM70KPSH YFM70KPXH 1 Trailer hitch receiver 1 UB1661E0 book Page 25 Thursday May 12 2016 2 47 PM ...

Page 58: ...ssory on 6 When the auxiliary DC jack is not being used cover it with the cap NOTICE ECB00121 Do not use accessories requiring more than the above maximum capacity This may overload 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 start ing may become difficult Do not use an automo...

Page 59: ...y a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 19 5 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 5 3 8 20 Final gear oil Check ATV for o...

Page 60: ...er free play and adjust if necessary 5 4 8 41 Control cables Make sure that operation is smooth Lubricate if necessary 8 49 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 50 Brake levers Mak...

Page 61: ...8 29 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU28533 Front and rear brakes Brake levers and brake pedal 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 Check for correct free play in the rear brake le ver and brake pedal If the free play is incorrect adjust i...

Page 62: ...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 EBU19815 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use the low pressure tire gauge to check and ad just tire pressures when the tires are cold Tire pressures...

Page 63: ...n the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended tire pressure Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum tire pressure Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi 1 Low pressure tire gauge UB1661E0 book Page...

Page 64: ...or this model by Yamaha Motor Manufacturing Corporation of America 1 Tire wear limit Front Manufacturer model CHENG SHIN C828 YFM70KDXH_AUS NZL YFM70KPAH MAXXIS MU19 YFM70KDXH_EUR FRA GBR YFM70KPHH YFM70KPSH YFM70KPXH Size AT25 x 8 12 Type Tubeless Rear Manufacturer model CHENG SHIN C828 YFM70KDXH_AUS NZL YFM70KPAH MAXXIS MU20 YFM70KDXH_EUR FRA GBR YFM70KPHH YFM70KPSH YFM70KPXH Size AT25 x 10 12 T...

Page 65: ...of handling braking and comfort Other tires rims sizes and combinations may not be appropriate EBU19841 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened EBU19851 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary UB1661E0 book Page 7 Thursday May 12 2016 2 47 PM ...

Page 66: ... on until the engine is started The following warning lights should come on for a few seconds then go off Coolant temperature warning light Engine trouble warning light Fuel level warning light for equipped mod els NOTICE ECB00826 To avoid possible damage do not operate the ATV if a warning light does not work as de scribed above 2 Apply the brake pedal and then shift the drive select lever into t...

Page 67: ...ttery energy Do not crank the engine more than 10 seconds on each attempt NOTICE ECB00164 For maximum engine life never accelerate hard when the engine is cold EBU36230 Operating the drive select lever and driving in reverse NOTICE ECB03330 Do not shift without coming to a complete stop and waiting for the engine to return to normal idle speed Damage to the engine or drivetrain may occur Shifting ...

Page 68: ...ople or ob stacles behind you When it is safe to proceed go slowly 1 Bring the ATV to a complete stop 2 Apply the brake pedal 3 Shift from neutral to reverse or from reverse to park and vice versa by moving the drive se lect lever along the shift guide 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park 1 2 3 4 5 6 L H N R P 1 Drive select lever 2 L Low range 3 H Hig...

Page 69: ... 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 ex cessive 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 clear ances During this period prolonged full throttle operation o...

Page 70: ...ne shift the drive select lever to the park position and then 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 easily 1 Bring the ATV to a stop by applying the brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to the park position EBU20911 Accessories and loading EBU20922 ...

Page 71: ...re responsible for injuries re lated to changes in the vehicle Keep the following in mind when considering an accessory or operating an ATV which has acces sories Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability ...

Page 72: ...t the tongue of the loaded trailer on the scale with the tongue at hitch height Ad just the load in the trailer if necessary to reduce the weight on the hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum ATV load limit MAXIMUM LOADING LIMIT ATV loading limit total weight of rider car go accessories and tongue 240 0 kg 530 lb Front carrier 50 0 kg 110 lb R...

Page 73: ...r your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills...

Page 74: ...7 1 7 EBU21142 RIDING YOUR ATV UB1661E0 book Page 1 Thursday May 12 2016 2 47 PM ...

Page 75: ...n on pages 2 1 2 6 Also read all warn ing and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01382 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types ...

Page 76: ...at are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WARNING Never carry a passenger Carrying a passenger on this ATV greatly reduces your ability to balance and contro...

Page 77: ...G Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01412 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating wi...

Page 78: ...each time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and mainte nance procedures and schedules described in the Owner s Manual WARNING Failure to inspect the ATV before riding it or failure to maintain it properly increases the possibility of an acci dent and equipment damage EWB01433 Speed limiter...

Page 79: ... centered side to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier vehicle ...

Page 80: ... your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident EWB01472 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rid er accessories and...

Page 81: ...the engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine ...

Page 82: ...faces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01512 While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles Watch carefully for other vehicles Make sure you UB1661E0 boo...

Page 83: ... may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01532 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary to ...

Page 84: ... flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where you cannot easily be seen Mount a cau tion flag on the ATV to make you more visible Watch carefully for other vehicles EWB01552 Do not ride in areas posted no trespassing Do not ride on private property without getting permission UB1661E0 book Page 11 Thur...

Page 85: ... release the throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident NOTICE ECB00252 Do not shift from low range to high range or vice versa without coming to a complete stop Damage to the engine or drive train may occur TURNING YOUR ATV WARNING EWB01772 Always follow proper pro...

Page 86: ...f your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throt tle 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 be gins to tip over to the outside whil...

Page 87: ...suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a...

Page 88: ...end If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause y...

Page 89: ...ore easily on extremely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble Improper braking can cause the wheels on the uphill side to come off the ground or cau se loss of trac...

Page 90: ...ther the front or rear brake because the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01633 Im...

Page 91: ...t may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill 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 obstacles in your path As you regain proper balance grad ually steer again in the direction you wish to travel C...

Page 92: ...ride your ATV without verifying that you have regained proper braking ability WARNING Wet brakes may have reduced stopping ability which could cause loss of control EWB02622 After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Also remove the drain plugs from the storage compartment and the V belt case to drain any water ...

Page 93: ...es such as lar ge rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to an upset or 1 Air filter case check hose 1 Storage compartment drain plug 1 1 1 V belt case drain plug 1 UB1661E0 book Page 20 Thursday ...

Page 94: ... slowly and be very cautious in order to re duce the chance of skidding or sliding out of control Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help...

Page 95: ... Position your weight over the front wheels for better control See page 7 12 If your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See page 7 12 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recomm...

Page 96: ... you discover that the ATV is going to tip over dismount on the uphill side See page 7 17 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter 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 until you have regained adequate braking ability S...

Page 97: ...rn off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 6 for more information about carbon monoxide WARNING EWB02691 B...

Page 98: ...uded in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s man...

Page 99: ... dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve c...

Page 100: ...ark arrester Clean 7 Air induction sys tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 UB1661E0 book Page 4 Thursday May 12 2016 2 47 PM ...

Page 101: ...s data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check operation and correct if necessary Check fluid level and ATV for fluid leakage and co...

Page 102: ...r wear cracks or other damage and re place if necessary 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 11 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 12 Stabilizer bushes Check for cracks or other damage and replace if necessary 13 Rear knuckle pivots Lubricate with lithium soap based greas...

Page 103: ...e and correct if neces sary 19 Engine oil filter car tridge Replace 20 Differential gear oil Change Check ATV for oil leakage and correct if neces sary 21 Final gear oil Change Check ATV for oil leakage and correct if neces sary 22 Cooling system Check coolant level and ATV for coolant leakage and correct if necessary Replace coolant Every 2 years NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whi...

Page 104: ...s every four years and if cracked or damaged 23 Moving parts and cables Lubricate 24 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 25 Front and rear brake switches Check operation and correct if necessary 26 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB ...

Page 105: ...nance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU34180 Panel A To remove the panel Pull upward on the areas shown 1 Panel A 2 Panel B 3 Panel C 4 Panel D 5 Panel F 2 1 3 4 5 1 Panel E 2 Panel G 2 1 UB1661E0 book Page 9 Thursday May 12 2016 2 47 PM ...

Page 106: ... the panel in the original position Panel B To remove the panel 1 Remove panel A 2 Remove the front carrier by removing the bolts 1 Panel A 1 1 Front carrier 2 Carrier bolt upper 1 2 2 UB1661E0 book Page 10 Thursday May 12 2016 2 47 PM ...

Page 107: ...ward to remove it To install the panel 1 Place the panel in the original position and then install the quick fasteners 1 Carrier bolt under the fenders 2 Carrier bolt lower 1 2 2 1 1 Panel B 2 Quick fastener 1 2 2 UB1661E0 book Page 11 Thursday May 12 2016 2 47 PM ...

Page 108: ...l 1 Remove the seat See page 4 21 2 Remove panel A 3 Remove the hoses from panel C 4 Remove the quick fasteners and bolts Tightening torques Carrier bolt upper 34 N m 3 4 kgf m 25 lb ft Carrier bolt lower 34 N m 3 4 kgf m 25 lb ft Carrier bolt under the fenders 7 N m 0 7 kgf m 5 1 lb ft 1 Hose 1 1 UB1661E0 book Page 12 Thursday May 12 2016 2 47 PM ...

Page 109: ...ll the panel upward to remove it TIP To ease removal of panel C shift the drive select lever into the reverse position To install the panel 1 Place the panel in the original position 1 Bolt 2 Quick fastener 1 1 2 1 Screw 1 1 UB1661E0 book Page 13 Thursday May 12 2016 2 47 PM ...

Page 110: ...operly connected and routed and are not pinched 3 Install panel A 4 Install the seat Panels D and E To remove a panel 1 Remove panels A and C 2 Remove the bolt and then pull the panel up ward to remove it 1 Panel D 2 Bolt 1 Panel E 2 Bolt 1 2 1 2 UB1661E0 book Page 14 Thursday May 12 2016 2 47 PM ...

Page 111: ...tion and then install the bolt 2 Install panels A and C Panels F and G To remove a panel 1 Remove the panel bolts footboard bolt and footboard nut 1 Panel F 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection UB1661E0 book Page 15 Thursday May 12 2016 2 47 PM ...

Page 112: ...ion To install a panel 1 Place the panel in the original position 2 Install the bolts and nut and then tighten them to the specified torques 1 Panel G 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection UB1661E0 book Page 16 Thursday May 12 2016 2 47 PM ...

Page 113: ...enance and lubri cation chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove panels A and C See page 8 9 2 Remove the storage compartment by remov ing the bolt 3 Remove the spark plug cap Tightening torques Panel bolt 4 0 N m 0 40 kgf m 2 9 lb ft Footboard nut 4 0 N m 0 40 kgf m 2 9 lb ft 1 Storage compartment 2 Bolt 1 Spark plu...

Page 114: ...plug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the vehicle 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 ...

Page 115: ...available when installing the spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible 3 Install the spark plug cap 4 Install the storage compartment as shown and then install the bolt 5 Install the panels 1 Spark plug gap Spark plug gap 0 8 0 9 mm 0 031 0 035 in Tightening torque Spar...

Page 116: ...vel 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least 10 minutes until the oil set tles for an accurate reading 3 Remove the access cover by turning it coun terclockwise 4 Remove the engine oil dipstick and then wipe it off with a clean rag 1 ...

Page 117: ...2 7 Insert the dipstick completely into the oil filler hole 8 Install the access cover by turning it clock wise To change the engine oil with or without oil fil ter cartridge replacement 1 Place the ATV on a level surface 2 Start the engine warm it up for several minu tes and then turn it off 3 Remove the access cover by turning it coun terclockwise 4 Place an oil pan under the engine to collect t...

Page 118: ...il filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer 8 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge 1 Engine oil drain bolt 2 Gasket 1 2 1 Oil filter cartridge 2 Oil filter wrench 1 2 UB1661E0 book Page 22 Thursday May 12 2016 2 47 PM ...

Page 119: ...orque with a torque wrench 10 Install panel F 11 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the spec ified torque 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 15 N m 1 5 kgf m 11 lb ft Tightening torque Engine oil drain bolt 22 N m 2 2 kgf m 16 lb ft 1 UB1661E0 book Page 23 Thursday May 12 2016 2 47 PM ...

Page 120: ...r oil leakage If oil is leaking immediately turn the engine off and check for the cause 14 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 15 Install the access cover by turning it clock wise EBU27307 Final gear oil The final gear case must be checked for oil leak age before each ride If any leakage is found have a Yamaha dealer check and repa...

Page 121: ... to raise it to the correct level 4 Check the gaskets for damage and replace them if necessary 5 Install the oil level check bolt the oil filler bolt and their gasket and then tighten the bolts to the specified torques 1 Final gear oil 2 Gasket 3 Final gear oil level check bolt 4 Correct oil level 1 2 4 3 1 Final gear oil filler bolt 2 Gasket Tightening torques Final gear oil level check bolt 10 N...

Page 122: ...in bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended final gear oil to the brim of the check hole as shown NOTICE Be sure no foreign material en ters the final gear case ECB00422 1 Final gear oil drain bolt 2 Gasket 1 2 Tightening torque Final gear oil drain bolt 23 N m 2 3 kgf m 17 lb ft 1 Final gear oil 2 Gasket 3 Final gear oil level check b...

Page 123: ... at the in tervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface 2 Remove the differential gear oil filler bolt and its gasket and then check the oil level in the differential gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil ...

Page 124: ... the drain bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended differential gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material en ters the differential gear case ECB00412 Tightening torque Differential gear oil filler bolt 23 N m 2 3 kgf m 17 lb ft 1 Differential gear oil drain bolt 2 Gasket 1 2 Tightening torque ...

Page 125: ...tervals specified in the periodic maintenance and lubrication chart EBU34201 To check the coolant level 1 Park the ATV on a level surface TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser voir TIP The coolant should be between the minimum and maximum level marks Recommended differential gear oil Se...

Page 126: ...of coolant replace it with coolant as soon as possible otherwise the cooling system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze con tent of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECB01012 TIP The radiator fan is automatically switched on or off according to the...

Page 127: ...er pressure Always place a thick rag over the cap when opening Allow any remaining pressure to escape before completely removing the cap 1 Park the ATV on a level surface 2 Remove panels A B C and D See page 8 9 3 Remove the footboard by removing the bolts and nuts 4 Remove the radiator cap 1 Footboard 2 Bolt and nut 3 Bolt 3 2 2 3 1 UB1661E0 book Page 31 Thursday May 12 2016 2 47 PM ...

Page 128: ...n remove the coolant drain bolt and its gasket Use a trough or a similar object as shown to prevent coolant from spilling on the engine guard 1 Radiator cap 1 Coolant drain bolt 2 Gasket 1 Trough 1 2 1 UB1661E0 book Page 32 Thursday May 12 2016 2 47 PM ...

Page 129: ...he bolt to the specified torque 11 Connect the coolant reservoir hose 12 Pour the recommended coolant into the radi ator until it is full 13 Pour the recommended coolant into the res ervoir to the maximum level mark and then install the reservoir cap NOTICE Mix anti freeze with distilled water only However if distilled water is not available soft water may be used for refilling Do not use hard wat...

Page 130: ...emoving it to allow all of the air to es cape from the air bleed bolt hole Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol antifreeze con taining corrosion inhibitors for aluminum engines Coolant quantity Radiator including all routes 1 76 L 1 86 US qt 1 55 Imp qt Coolant reservoir up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt 1 Water pump air bl...

Page 131: ...as dropped after the engine has cooled add sufficient coolant until it reaches the top of the radiator and then in stall the radiator cap 23 Start the engine and then check for coolant leakage TIP If any leakage is found have a Yamaha dealer check the cooling system 24 Install the footboard by installing the bolts and nuts and then tighten them to the speci fied torques 1 Cylinder head air bleed b...

Page 132: ...els 1 Footboard nut 2 Footboard bolt A 3 Footboard bolt B 3 1 2 1 Tightening torques Footboard nut 4 0 N m 0 40 kgf m 2 9 lb ft Footboard bolt A 4 0 N m 0 40 kgf m 2 9 lb ft Footboard bolt B 8 N m 0 8 kgf m 5 8 lb ft 4 1 2 3 UB1661E0 book Page 36 Thursday May 12 2016 2 47 PM ...

Page 133: ...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 fil ter case 1 Place the ATV on a level surface 2 Remove the seat See page 4 21 3 Remove the air filter case cover by unhooking the air filter case cover holders 4 Pull the air filter element out of the air filter case 1 Air filter case check hose 1 1 Air f...

Page 134: ...onge material Never use low flash point sol vents or gasoline to clean the sponge ma terial because the engine could catch fire or explode EWB01942 7 Squeeze the excess solvent out of the sponge material and let it dry NOTICE Do not twist the sponge material when squeezing it ECB00442 1 Air filter element 1 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate 3 2 1 UB1661E0...

Page 135: ... engine wear and possible engine damage Additionally the fuel injection system would be affected resulting in poor engine performance and possible over heating ECB00763 12 Install the seat TIP The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas Each time the air filter element main tenance is perf...

Page 136: ...e of the tailpipe housing 4 Check the gasket for damage and replace it if necessary 5 Make sure the gasket is properly positioned then insert the tailpipe into the muffler and align the bolt holes 6 Install the bolts and tighten them to the spec ified torque 1 Tailpipe bolt 1 1 1 Gasket 2 Spark arrester 3 Tailpipe Tightening torque Tailpipe bolt 10 N m 1 0 kgf m 7 2 lb ft 3 2 1 UB1661E0 book Page ...

Page 137: ...e case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the water may affect other engine parts EBU29703 Adjusting the throttle lever free play The throttle lever free play should be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The throttle lever free play should measure 3 0 5 0 ...

Page 138: ...n the periodic maintenance and lu brication chart EBU29602 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be performed by a Yamaha dealer WARNING EWB02572 Operating with improperly serviced or adjust ed brakes could lead to a loss in braking ability and an accident EBU28414 Checking the front brake pads and rear brake friction plates The front brake pa...

Page 139: ...the wear indica tor groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set TIP The wheels need to be removed to check the brake pads See page 8 64 EBU30321 Rear brake friction plates The rear brake friction plates must be checked and if necessary replaced by a Yamaha dealer at the intervals specified i...

Page 140: ...e rubber seals may deteriorate causing leakage Refill with the same type of brake fluid Add ing a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the flu id and may result in vapor lock NOTICE ECB01161 Brake fluid may damage painted surfaces or pl...

Page 141: ... Checking the front brake lever free play The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart The brake lever should have no free play as shown If there is free play have a Yamaha dealer check the brake system EBU34242 Adjusting the rear brake lever and brake pedal free play The rear brake lever and brake pedal free play must be ch...

Page 142: ...brake lever free play could be ob tained as described above skip steps 3 8 3 Fully turn the adjusting bolt in direction a to loosen the brake cable 4 Slide the rubber cover back 5 Loosen the brake cable adjuster locknut 1 Brake lever free play 1 Locknut 2 Brake lever free play adjusting bolt 1 a b 1 2 1 Brake cable adjuster locknut 2 Brake lever free play adjusting nut 3 Rubber cover 2 3 1 a b UB1...

Page 143: ...e brake pedal free play The brake pedal free play should measure 12 0 17 0 mm 0 47 0 67 in If the free play is incorrect adjust it as follows 1 Remove panel G 2 Loosen the locknut 3 To increase the brake pedal free play turn the brake pedal free play adjusting nut in direc tion a To decrease the brake pedal free play turn the adjusting nut in direction b 4 Tighten the locknut 5 Install the panel 1...

Page 144: ...levers should come on just be fore braking takes effect The rear brake light switch can be adjusted as fol lows but the front brake light switch should be ad justed by a Yamaha dealer Turn the rear brake light switch adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn th...

Page 145: ...peration of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an accident or collision EBU28712 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers...

Page 146: ...ecked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel G See page 8 9 Recommended lubricants Front brake lever Silicone grease Rear brake lever Lithium soap based grease Recommended lubricant Lithium soap based grease UB1661E0 book Page 50 Thursday May 12 2016 2 47 PM ...

Page 147: ...y in a wheel hub or if a wheel does not turn smooth ly have a Yamaha dealer check the wheel hub bearings EBU25023 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bush es if necessary UB1661E0 book Page 51 Thursday May 12 2016 2 47 PM ...

Page 148: ...se a grease gun EBU25094 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe riodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun Recommended lubricant Lithium soap based grease 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 UB1661E0 book Page 52 Thursday M...

Page 149: ...nger ous as it contains sulfuric acid which can cau se severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention...

Page 150: ...Remove the battery holding plate by remov ing the nuts 4 Disconnect the negative battery lead first then the positive battery lead by removing their bolt NOTICE When removing the bat tery the main switch must be off and the negative lead must be disconnected be fore the positive lead ECB01002 1 Front carrier 2 Carrier bolt upper 1 2 2 1 Carrier bolt under the fenders 2 Carrier bolt lower 1 2 2 1 U...

Page 151: ...ll damage the battery To store the battery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00941 Always keep the battery charged Storing a discharged battery can cause permanent bat tery damage ...

Page 152: ... Install the battery holding plate by installing the nuts 4 Install the front carrier by installing the bolts and tightening them to the specified torques 5 Install the panel 1 Positive battery lead red 2 Negative battery lead black 1 2 Tightening torques Carrier bolt upper 34 N m 3 4 kgf m 25 lb ft Carrier bolt lower 34 N m 3 4 kgf m 25 lb ft Carrier bolt under the fenders 7 N m 0 7 kgf m 5 1 lb ...

Page 153: ...ll elec trical circuits 1 Fuse box 2 Main fuse 3 EPS fuse for EPS model 4 Fuel injection system spare fuse 5 Fuel injection system fuse 2 3 4 5 1 1 Headlight fuse 2 Signaling system fuse 3 Radiator fan motor fuse 4 Ignition fuse 5 Four wheel drive motor fuse YFM70KPSH 6 Auxiliary DC jack fuse 7 Spare fuse 8 Spare fuse YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH 1 2 3 4 5 6 8 7 UB1661E0 book Page 57 Th...

Page 154: ...amage to the electrical system which could lead to a fire EWB02173 3 Turn the key to on and turn on the elec trical circuits to check if the devices operate Specified fuses Main fuse 40 0 A Headlight fuse 10 0 A YFM70KDXH 15 0 A YFM70KPAH YFM70KPHH YFM70KPSH YFM70KPXH Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A YFM70KPSH Signaling system fuse 10 0 A Auxiliary DC jack fuse 10 0 A Radiat...

Page 155: ...ace it with the specified bulb as follows Left and right headlight bulbs 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the bulb cover by pulling it off 3 Remove the socket by pushing it in and turn ing it counterclockwise 1 Cover at the rear of the headlight 1 1 Bulb cover 1 Socket 1 1 UB1661E0 book Page 59 Thursday May 12 2016 2 47 PM ...

Page 156: ... pushing it in and turning it clockwise 7 Install the bulb cover and the cover at the rear of the headlight NOTICE Make sure the bulb cover is securely fitted over the sock et and seated properly ECB03320 8 Adjust the headlight beam if necessary Handlebar mounted light bulb YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH 1 Remove the handlebar mounted light cover by removing the quick fasteners 2 Remove t...

Page 157: ...ency of the glass luminosity of the bulb and bulb life Thoroughly clean off any dirt and fin gerprints using a cloth moistened with al cohol or thinner ECB00653 6 Install the socket by pushing it in and turning it clockwise 7 Install the bulb cover NOTICE Make sure the bulb cover is securely fitted over the socket and seated properly ECB03320 1 Bulb cover 1 Socket 1 1 1 Do not touch the glass part...

Page 158: ...ing a headlight beam NOTICE ECB00691 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b 1 Handlebar mounted light cover 1 1 Headlight beam adjusting screw b a 1 UB1661E0 book Page 62 Thursday May 12 2016 2 47 PM ...

Page 159: ... follows 1 Remove the tail brake light bulb holder to gether with the bulb by turning it counter clockwise 2 Remove the burnt out bulb by pushing it in and turning it counterclockwise 1 Handlebar mounted light beam adjusting screw b a 1 1 Tail brake light bulb holder 1 Tail brake light bulb 1 1 UB1661E0 book Page 63 Thursday May 12 2016 2 47 PM ...

Page 160: ...d place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU36241 Installing a wheel 1 Install the wheel and the nuts TIP The arrow mark on the tire must point to ward the rotating direction of the wheel For YFM70KDXH YFM70KPXH YFM70KPHH YFM70KPAH tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side towards the wheel ...

Page 161: ...to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02281 Do not smoke when checking the fuel system Fuel can ignite or explode causing se...

Page 162: ...e the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Check the compression Dry Wet Operate the electric starter Have a Yamaha dealer check the ATV The engine does not start Check the ignition Operate the electric starter 2 Battery The engine turns over qui...

Page 163: ...r can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If the engine overheats ...

Page 164: ...ion dry out the linings EWB02312 NOTICE Excessive wa ter pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure de tergent applications such as those avail able in coin operated car washers ECB00712 4 Once most of the dirt has been hosed off wash all surfaces with wa...

Page 165: ...the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil e Remove the spark plug cap ...

Page 166: ... it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more infor mation on storing the battery see page 8 53 TIP Make any necessary repairs before storing the ATV UB1661E0 book Page 3 Thursday May 12 2016 2 47 PM ...

Page 167: ... A YFM70KDXH_EUR FRA GBR YFM70KPHH YFM70KPSH YFM70KPXH Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s YFM70KDXH_EUR FRA GBR YFM70KPHH YFM70KPSH YFM70KPXH Uncertainty of measurement 0 0 m s YFM70KPHH YFM70KPSH YFM70KPXH 0 1 m s YFM70KDXH_EUR FRA GBR Vibration on handle EN1032 ISO5008 Will not exceed 2 5 m s YFM70KDXH_EUR FRA GBR YFM70KPHH YFM70KPSH YFM70KPXH Uncertainty of measurement 0 3...

Page 168: ...Shaft Drive Oil Part No ACC SHFTL PL 32 or SAE 80 API GL 4 Hypoid gear oil Quantity 0 22 L 0 23 US qt 0 19 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator including all routes 1 76 L 1 86 US qt 1 55 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 18 0 L 4 75 US gal...

Page 169: ... 8 12 Manufacturer model CHENG SHIN C828 YFM70KDXH_AUS NZL YFM70KPAH MAXXIS MU19 YFM70KDXH_EUR FRA GBR YFM70KPHH YFM70KPSH YFM70KPXH Rear tire Type Tubeless Size AT25 x 10 12 Manufacturer model CHENG SHIN C828 YFM70KDXH_AUS NZL YFM70KPAH MAXXIS MU20 YFM70KDXH_EUR FRA GBR YFM70KPHH YFM70KPSH YFM70KPXH Loading Maximum loading limit 240 0 kg 530 lb Total weight of rider cargo accessories and tongue T...

Page 170: ...t foot operation Front suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 193 mm 7 6 in Rear suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 232 mm 9 1 in Electrical system Ignition system TCI Charging system AC magneto Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Headlight s Bulb type Krypton bulb ...

Page 171: ...ur wheel drive indicator LCD YFM70KPAH YFM70KPHH YFM70KPXH Engine trouble warning light LED High range indicator light LED YFM70KPAH YFM70KPHH YFM70KPSH YFM70KPXH Low range indicator light LED YFM70KPAH YFM70KPHH YFM70KPSH YFM70KPXH Differential gear lock indicator light LED YFM70KPSH Fuses Main fuse 40 0 A Fuel injection system fuse 15 0 A EPS fuse 40 0 A YFM70KPAH YFM70KPHH YFM70KPSH YFM70KPXH H...

Page 172: ...rs that influence the actual level of exposure of work force include the characteristics of the work room the other sources of noise etc i e the number of machines and other adjacent process es and the length of time for which an operator is exposed to the noise Also the permissible expo sure level can vary from country This information however will enable the user of the machine to make a better ...

Page 173: ...L LABEL INFORMATION EBU26031 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to iden tify your ATV EBU26051 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yam...

Page 174: ...11 2 11 1 Model label 1 UB1661E0 book Page 2 Thursday May 12 2016 2 47 PM ...

Page 175: ...D Differential gear lock indicator YFM70KPSH 4 6 Differential gear oil 5 3 8 27 Drive lever YFM70KDXH YFM70KPXH YFM70KPHH YFM70KPAH 4 15 Drive select lever 4 19 Drive select lever and driving in reverse 6 2 E Engine break in 6 4 Engine oil 5 3 Engine oil and oil filter cartridge 8 20 Engine stop switch 4 10 Engine trouble warning light 4 4 EPS warning light for EPS model 4 5 F Final gear oil 5 3 8...

Page 176: ...t locations 3 1 R Rear brake adjusting the lever pedal free play 8 45 Rear knuckle pivots lubricating 8 52 Reverse indicator light 4 3 Riding your ATV 7 1 S Safety information 2 1 Seat 4 21 Shock absorber assemblies adjusting the front and rear YFM70KPXH YFM70KPHH YFM70KPSH YFM70KPAH 4 24 Spark arrester cleaning 8 39 Spark plug checking 8 17 Specifications 10 1 Speed limiter 4 17 Stabilizer bushes...

Page 177: ...12 3 12 W Wheel hub bearings checking 8 51 Wheel installing 8 64 Wheel removing 8 64 UB1661E0 book Page 3 Thursday May 12 2016 2 47 PM ...

Page 178: ... APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS 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 LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND...