Yamaha KODIAK 700, Owner'S Manual

Page 1: ...EL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO B16 F8199 62 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 2017 04 0 5 1 CR E F S ...

Page 3: ...important safety information WARNING OWNER S MANUAL YFM70KDXJ YFM70KDHJ YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPSJ This ATV should not be ridden by anyone under 16 years of age B16 F8199 62 E0 UB1662E0 book Page 1 Monday April 17 2017 11 39 AM ...

Page 4: ... 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 Title and or number and date of issue of standards and or speci...

Page 5: ...od basic 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 ...

Page 6: ...the figures shown in this manual This is the 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 vehic...

Page 7: ...heck your local riding laws and regulations before operating this ATV EBU17411 YFM70KDXJ YFM70KDHJ YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPSJ OWNER S MANUAL 2017 by Yamaha Motor Co Ltd 1st edition April 2017 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A UB1662E0 book Page 1 Monday April 17 2017 11 ...

Page 8: ... 4 13 Throttle lever 4 14 Speed limiter 4 15 Front brake lever 4 15 Brake pedal and rear brake lever 4 16 Drive select lever 4 16 Fuel tank cap 4 17 Fuel 4 17 Seat 4 19 Storage compartment 4 20 Front carrier 4 21 Rear carrier 4 22 Front and rear shock absorbers YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPSJ 4 22 Trailer hitch YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPSJ 4 23 Auxiliary DC jack 4 24 PRE OPERATI...

Page 9: ... 8 1 Owner s manual and tool kit 8 2 Periodic maintenance chart Emission control system 8 3 Periodic maintenance chart General maintenance and lubrication 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 element 8 37 Cleaning the spark arrester 8 39 V belt...

Page 10: ...ckle 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 CONSUMER INFORMATION 11 1 Identification n...

Page 11: ...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 UB1662E0 book Page 1 Monday April 17 2017 11 39 AM ...

Page 12: ...1 2 1 For Europe 1 2 3 4 5 11 9 10 7 8 6 UB1662E0 book Page 2 Monday April 17 2017 11 39 AM ...

Page 13: ...5 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 UB1662E0 book Page 3 Monday April 17 2017 11 39 AM ...

Page 14: ...500 SHINGAI IWATA JAPAN YFM700FWBD 36 0 kW 307 kg 2017 2SM F155A 20 YAMAHA 1HP F811R 00 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWBD 36 0 kW 313 kg 2017 B32 F155A 30 E10 B42 F817K 00 6 YFM70KDXJ YFM70KDHJ 6 YFM70KPXJ 6 YFM70KPAJ YFM70KPHJ YFM70KPSJ 7 8 9 UB1662E0 book Page 4 Monday April 17 2017 11 39 AM ...

Page 15: ...1 5 1 1P0 F816R 00 YAMAHA B16 F816N 01 4 kg 9 lb 10 11 UB1662E0 book Page 5 Monday April 17 2017 11 39 AM ...

Page 16: ...m 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 liquids Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control UB1662E0 book Pa...

Page 17: ...rol 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 related items Make sure you do not exceed the load limits Overloading can cause loss of control Loss of c...

Page 18: ...1 8 1 For Oceania 3 5 4 9 6 7 8 1 2 UB1662E0 book Page 8 Monday April 17 2017 11 39 AM ...

Page 19: ...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 UB1662E0 book Page 9 Monday April 17 2017 11 39 AM ...

Page 20: ... 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 21: ...n 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 MA...

Page 22: ...ld 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 23: ...ing 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 Shift...

Page 24: ...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 25: ...sary 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 you...

Page 26: ...ange any of 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 found in the Loading section page 6 6 when mounting acces sories Never install accessories that would impair the performance of your ATV Carefully in...

Page 27: ...nd you can quickly be overcome and unable to save yourself Also 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...

Page 28: ... 6 Rear brake light switch 7 Engine oil dipstick 8 Oil filter cartridge 9 Coolant reservoir 5 1 2 3 4 7 8 6 9 1 Rear shock absorber 2 Fuel tank cap 3 Owner s tool kit 4 Storage compartment 5 Spark plug 6 Front shock absorber 7 Brake pedal 8 V belt case drain plug 5 1 6 2 3 4 7 8 UB1662E0 book Page 1 Monday April 17 2017 11 39 AM ...

Page 29: ... 7 Front brake fluid reservoir 8 Front brake lever 9 Throttle 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 Multi function display 6 Front brake fluid reservoir 7 On Command 4WD switches 8 Front brake lever 9 Throttle lever 10 Auxiliary DC jack 11 Main switch 1 2 3 5 6 7 8 9 1011 4 UB1662E0 book Page 2 ...

Page 30: ...ystems are off The key can be re moved EBU26697 Indicator lights and warning lights YFM70KDXJ YFM70KDHJ 1 Main switch 1 1 Fuel level warning light 2 Engine trouble warning light 3 Coolant temperature warning light 4 Neutral indicator light N 5 Reverse indicator light R 6 Park indicator light P 7 Four wheel drive indicator light 1 2 3 4 5 6 7 UB1662E0 book Page 1 Monday April 17 2017 11 39 AM ...

Page 31: ...l position EBU17831 Reverse indicator light This indicator light comes on when the transmis sion is in the reverse position EBU17971 Park indicator light This indicator light comes on when the transmis sion is in the park position 1 Differential gear lock indicator light DIFF LOCK 2 Low range indicator light L 3 High range indicator light H 4 Neutral indicator light N 5 Reverse indicator light R 6...

Page 32: ...ing light is on will damage the engine EBU29933 Fuel level warning light YFM70KDXJ YFM70KDHJ This warning light comes on when the fuel level drops below approximately 4 0 L 1 06 US gal 0 88 Imp gal When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked by setting the engine stop switch to and turning the key to on The warning light should come on for...

Page 33: ... after the engine is started the EPS sys tem may not be working correctly When this oc curs have a Yamaha dealer check the EPS system The electrical circuit of the warning light can be checked by turning the key to on If the warning light does not come on have a Yamaha dealer check the electrical circuit TIP If the engine is stopped using the engine stop switch and the key is in the on position th...

Page 34: ...M70KPHJ YFM70KPSJ This icon and this indicator light come on when the drivetrain is set to 4WD with the differential gear locked TIP When the On Command differential gear lock switch is set to LOCK or 4WD the icon and the DIFF LOCK indicator light will flash until the differential gear is completely locked or un locked Turn the handlebar or start moving to help the differential lock to engage or d...

Page 35: ...d since they were last reset The tripmeters can be used to record the distance traveled on a single trip or to estimate 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 ...

Page 36: ...he amount of fuel in the fuel tank The display segments of the fuel gauge disappear 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 le...

Page 37: ...y indicates 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 EBU18067 Handlebar switches YFM70KDXJ YFM70KDHJ 1 Error code display 2 Engine trouble warning light 1 2 1 Light switch OFF 2 Engine stop switch 3 Start switch...

Page 38: ...gine when it is running Use this switch to stop the engine in an emergency situa tion The engine will not start or run when this switch is set to 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE 5 Horn switch 4 1 3 2 5 1 On Command drive switch 2WD 4WD 2 On Command drive switch 4WD LOCK 3 Drive switch lock lever 2WD 4WD LOCK 4WD 3 3 2 1 UB1662E0 book Page 9 Monday ...

Page 39: ... of time The battery may discharge to the point that the starter will not have enough power to crank the engine If this should happen remove the bat tery and recharge it See page 8 53 EBU18171 Horn switch Press the switch to sound the horn EBU18192 Override switch OVERRIDE YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPSJ Top speed is normally limited when operating in differential gear lock If conditions r...

Page 40: ...D YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPSJ Stop the ATV and push this switch to change from two wheel drive to four wheel drive or vice versa Select the appropriate drive according to the ter rain and riding conditions 2WD two wheel drive power is supplied to the rear wheels only giving a smooth ride and fuel economy 4WD four wheel drive power is supplied to the front and rear wheels giving increas...

Page 41: ...top the ATV before changing from four wheel drive to four wheel drive differen tial gear lock or vice versa The ATV handles differently in four wheel drive than in differential gear lock in some circum stances Changing from four wheel drive to differential gear lock or vice versa while mov ing may cause the ATV to handle differently un expectedly This could distract the operator and increase the r...

Page 42: ...dif ferential gear lock speed limiter See page 4 10 WARNING EWB00141 Always ride at a slow speed when the ATV is in differential gear lock 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 ...

Page 43: ...r vice versa while moving may cause the ATV to unexpectedly handle differently This could distract the oper ator and increase the risk of losing control and of causing an accident EBU18284 Throttle lever Push the throttle lever to increase engine speed and the speed of the ATV Because the throttle is spring loaded the ATV will decelerate and the en gine will return to an idle any time the throttle...

Page 44: ... 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 throttle could cause throttle cable damage or improper throttle operation You could lose control resulting in an acc...

Page 45: ...he 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 EBU18613 Drive select lever The drive select lever is used to shift the transmis sion into the low range high range neutral re verse and park positions See page 6 2 for drive select lever operation 1 Brake pedal 1 1 Rear brake lever 1 UB1662E0 ...

Page 46: ... no one is sitting on the vehicle Nev er refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands wh...

Page 47: ...l may deteriorate painted surfaces or plastic parts ECB00982 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed 1 Fuel tank filler tube 2 Maximum fuel level Recommended fuel Regular unleaded gasoline only Fuel tank capacity 18 0 L 4 75 US gal 3 96 Imp gal Fuel reserve amount 4 0 L 1 06 US gal 0 88 Imp gal 2 1 1 EN228 fuel identification mark E10 1 UB1662E0 book Page 18 Mon...

Page 48: ... unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoline with a 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 ext...

Page 49: ... ECB02320 Do not store metal or sharply edged objects like tools in the storage compartment If they must be stored wrap them in appropriate cushion material to prevent damaging the 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 UB1662E0 boo...

Page 50: ...d the maximum load of 240 0 kg 530 lb for the vehicle TIP A drain 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 1 Sto...

Page 51: ...setting Uneven adjustment can cause poor handling and loss of stability 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...

Page 52: ... can be obtained at a Yamaha dealer See page 6 6 for precaution in formation 1 Special wrench Spring preload setting Minimum soft 1 YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ Standard 2 YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ Maximum hard 5 YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ 1 Trailer hitch receiver 1 UB1662E0 book Page 23 Monday April 17 2017 11 39 AM ...

Page 53: ...ccessory off 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 auto...

Page 54: ... 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 17 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 oi...

Page 55: ...r 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 Make...

Page 56: ...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 57: ...maha dealer correct if necessary EBU19816 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use a tire pressure gauge to check and adjust tire air pressure when the tires are cold The tire air pressure must be equal on both sides WARNING Operation of this vehicle with im proper tire pressure may cause severe injury...

Page 58: ...r If the tire is damaged or the tire tread depth de creases to 3 mm 0 12 in or less replace the tire Tire information This ATV is equipped with tubeless tires and tire air valves After extensive tests only the tires list ed below are approved for this model by Yamaha WARNING EWB02552 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent 1 Low pressure tir...

Page 59: ...ts lights and switches Check that all instruments lights and switches are working properly Correct if necessary Front Manufacturer model CHENG SHIN C828 YFM70KDXJ_AUS NZL YFM70KPXJ_AUS NZL MAXXIS MU19 YFM70KDHJ YFM70KDXJ_EUR FRA GBR YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ_EUR FRA GBR Size AT25 x 8 12 Type Tubeless Rear Manufacturer model CHENG SHIN C828 YFM70KDXJ_AUS NZL YFM70KPXJ_AUS NZL MAXXIS M...

Page 60: ...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 th...

Page 61: ...tery 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 N...

Page 62: ...ple 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 High...

Page 63: ...r the first 320 km 200 mi or 20 hours During this period the various parts in the engine wear and polish themselves to the cor rect operating clearances Avoid prolonged full throttle operation or any condition that might re sult in engine overheating 0 160 km 0 100 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not oper ate it at one set thrott...

Page 64: ...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 Genuine Yamaha Accessories Choosing accessories for your ATV is an impor tant decision Genuine Yamaha Accessories which are available only from a Yamaha dealer have been designed tested and approved by Yamaha for use on your ATV Many compa...

Page 65: ...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 to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when ...

Page 66: ...d does not interfere with con trols or 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 u...

Page 67: ...7 1 7 EBU21142 RIDING YOUR ATV UB1662E0 book Page 1 Monday April 17 2017 11 39 AM ...

Page 68: ...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 69: ...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 70: ...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 71: ...ach 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 72: ... 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 73: ... 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 74: ...he 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 p...

Page 75: ...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 UB1662E0 boo...

Page 76: ...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 c...

Page 77: ...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 UB1662E0 book Page 11 Monda...

Page 78: ...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 proc...

Page 79: ...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 80: ...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 81: ...o climb or descend 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 whic...

Page 82: ...re 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 tract...

Page 83: ...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 84: ... 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 CR...

Page 85: ...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 86: ...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 UB1662E0 book Page 20 Monday Ap...

Page 87: ... 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 88: ... 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 89: ...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 Se...

Page 90: ...Turn 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...

Page 91: ...ded 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 manu...

Page 92: ...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 clearance and adjust if necessary Every...

Page 93: ...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 UB1662E0 book Page 4 Monday April 17 2017 11 39 AM ...

Page 94: ...lls 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 correct if necessary Repla...

Page 95: ... 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 grease...

Page 96: ...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 97: ... 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 I...

Page 98: ...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 UB1662E0 book Page 9 Monday April 17 2017 11 39 AM ...

Page 99: ...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 UB1662E0 book Page 10 Monday April 17 2017 11 39 AM ...

Page 100: ...ard 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 UB1662E0 book Page 11 Monday April 17 2017 11 39 AM ...

Page 101: ...l 1 Remove the seat See page 4 19 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 2 lb ft 1 Hose 1 1 UB1662E0 book Page 12 Monday April 17 2017 11 39 AM ...

Page 102: ...l 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 UB1662E0 book Page 13 Monday April 17 2017 11 39 AM ...

Page 103: ...perly 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 UB1662E0 book Page 14 Monday April 17 2017 11 39 AM ...

Page 104: ...ion 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 UB1662E0 book Page 15 Monday April 17 2017 11 39 AM ...

Page 105: ...on 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 UB1662E0 book Page 16 Monday April 17 2017 11 39 AM ...

Page 106: ...nance 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 3 0 lb ft Footboard nut 4 0 N m 0 40 kgf m 3 0 lb ft 1 Storage compartment 2 Bolt 1 Spark plug...

Page 107: ...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 108: ...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 109: ...ngine oil level 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 warm up the engine and then wait at least 10 minutes until the oil settles 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 Access cover ...

Page 110: ... 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 th...

Page 111: ...l 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 UB1662E0 book Page 22 Monday April 17 2017 11 39 AM ...

Page 112: ...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 UB1662E0 book Page 23 Monday April 17 2017 11 39 AM ...

Page 113: ...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 114: ...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 115: ...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 116: ... 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 117: ... 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 118: ...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 119: ...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 120: ...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 UB1662E0 book Page 31 Monday April 17 2017 11 39 AM ...

Page 121: ...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 UB1662E0 book Page 32 Monday April 17 2017 11 39 AM ...

Page 122: ...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 123: ...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 124: ...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 125: ...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 3 0 lb ft Footboard bolt A 4 0 N m 0 40 kgf m 3 0 lb ft Footboard bolt B 8 N m 0 8 kgf m 5 9 lb ft 4 1 2 3 UB1662E0 book Page 36 Monday April 17 2017 11 39 AM ...

Page 126: ... 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 19 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 filter case...

Page 127: ...aning solvent Never use low flash point solvents or gasoline because the engine could catch fire or explode EWB01943 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 UB1662E0 book Page 38 Monday April 17 2...

Page 128: ...ter element removed Doing so would al low unfiltered air to enter the engine caus ing rapid 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 Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstruction...

Page 129: ... 4 Check the gasket for damage Replace if nec essary 5 Install the gasket onto the tailpipe then insert the tailpipe into the muffler and align the bolt holes 6 Install the bolts and tighten to the specified torque EBU23932 V belt case drain plug After riding in water deep enough to allow it to en ter the V belt case remove the V belt case drain plug to drain the water from the case TIP If water d...

Page 130: ...just if necessary 1 Slide the rubber cover back 2 Loosen the locknut 1 V belt case drain plug 1 1 Rubber cover 2 Throttle lever free play adjusting bolt 3 Locknut 4 Throttle lever free play Throttle lever free play 3 0 5 0 mm 0 12 0 20 in 2WD 4WD 3 2 1 4 b a UB1662E0 book Page 41 Monday April 17 2017 11 39 AM ...

Page 131: ...RNING 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 pads and the rear brake friction plates must be checked for wear at the intervals specified in the periodic maintenance and lubrica tion chart TIP This ATV is equipped with a wet multiple ...

Page 132: ...he intervals specified in the periodic maintenance and lubrication chart EBU29844 Checking the brake fluid level Before riding check that the brake fluid is above the minimum level mark Replenish the brake fluid if necessary TIP Straighten the handlebars for an accurate reading 1 Wear indicator groove 1 Minimum level mark Specified brake fluid DOT 4 2WD 4WD 1 UB1662E0 book Page 43 Monday April 17 ...

Page 133: ...moving Use only DOT 4 brake fluid from a sealed contain er Use only the specified brake fluid otherwise the 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 poin...

Page 134: ... and brake pedal free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart Adjusting the brake lever free play Measure the brake lever free play as shown If the free play is incorrect adjust it as follows 1 Loosen the locknut at the brake lever 1 No brake lever free play 1 Brake lever free play Brake lever free play 6 0 7 0 mm ...

Page 135: ... adjuster locknut 6 To increase the brake lever free play turn the brake lever free play adjusting nut in direction a To decrease the brake lever free play turn the adjusting nut in direction b 7 Tighten the brake cable adjuster locknut 8 Slide the rubber cover to its original position 9 Tighten the locknut at the brake lever Adjusting the brake pedal free play Measure the brake pedal free play as...

Page 136: ...ake 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 Brake pedal free play Brake pedal free play 12 0 17 0 mm 0 47 0 67 in 1 1 Brake pedal free play adjusting nut 2 Locknut 2 a b 1 UB1662E0 book Page 47 Monday April 17 2017 11 39 AM ...

Page 137: ...evers 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 the...

Page 138: ...eration 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 139: ...cked 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 UB1662E0 book Page 50 Monday April 17 2017 11 39 AM ...

Page 140: ... 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 UB1662E0 book Page 51 Monday April 17 2017 11 39 AM ...

Page 141: ...quipped with a grease nipple use a grease gun EBU25095 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 Recommended lubricant Lithium soap based grease 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 UB1662E0 book Page 52 Monday April 17 2017 11 39 AM ...

Page 142: ...ctrolyte or to add distilled water However the battery lead connections need to be checked and tightened and the bat tery terminals cleaned if corroded If the battery seems to have discharged recharge it as soon as possible TIP Wear gloves and eye protection in a ventilated area away from sparks and open flames Wash hands after handling It is recommended to have the battery serviced by a Yamaha de...

Page 143: ... vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ignition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN To remove the battery 1 Remove panel A See page 8 9 2 Remove the front carrier by removing the bolts 1 Fr...

Page 144: ...recommended charging rate as specified on the battery itself Select a suitable charger and follow the manu facturer s instructions NOTICE ECB00933 To charge a VRLA valve regulated lead acid battery a special battery charger is required Using a conventional battery charger will dam age the battery To store the battery If the ATV will not be used for more than one month remove the battery fully char...

Page 145: ...ad by installing their bolt NOTICE When installing the bat tery the main switch must be off and the positive lead must be connected before the negative lead ECB01111 3 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 1 Positive battery lead red 2 Negative battery lead black Tightening torques C...

Page 146: ...essary as follows 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 YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPSJ 6 Auxiliary DC jack fuse 7 Spare fuse 8 Spare fuse YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPSJ 1 2 3 4 5 6 8 7 ...

Page 147: ... fuse or a substitute object can cause damage to the electrical system which could lead to a fire EWB02173 4 Turn on the main switch and start the engine Specified fuses Main fuse 40 0 A Headlight fuse 10 0 A YFM70KDHJ YFM70KDXJ 15 0 A YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ Signaling system fuse 10 0 A...

Page 148: ... 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 UB1662E0 book Page 59 Monday April 17 2017 11 39 AM ...

Page 149: ... 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 YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPSJ 1 Remove the handlebar mounted light cover by removing the quick fasteners 2 Remove t...

Page 150: ...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 151: ...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 UB1662E0 book Page 62 Monday April 17 2017 11 39 AM ...

Page 152: ...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 UB1662E0 book Page 63 Monday April 17 2017 11 39 AM ...

Page 153: ...lace a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU36243 Installing a wheel 1 Install the wheel with the arrow mark pointing in the forward rotating direction of the wheel and then install the wheel nuts TIP For YFM70KDXJ YFM70KDHJ YFM70KPXJ be sure to install the nuts with their tapered side towards the wheel 1 Wheel nut 1 1 1 Arrow mark 2 Forward rotatin...

Page 154: ...o 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 sev...

Page 155: ...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 156: ... 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 a...

Page 157: ...on 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 war...

Page 158: ...he following steps to protect the en gine from internal corrosion a Remove 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 sta...

Page 159: ...9 3 9 8 Remove the battery and fully charge it See page 8 53 UB1662E0 book Page 3 Monday April 17 2017 11 39 AM ...

Page 160: ... dB A YFM70KDHJ YFM70KDXJ_EUR FRA GBR YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ_EUR FRA GBR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s YFM70KDHJ YFM70KDXJ_EUR FRA GBR YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ_EUR FRA GBR Uncertainty of measurement 0 0 m s YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ_EUR FRA GBR 0 1 m s YFM70KDHJ YFM70KDXJ_EUR FRA GBR Vibration on handle EN1032 ISO5008 Will no...

Page 161: ...ft Drive Oil Part No ACC SHFTL PL 32 Quantity 0 52 L 0 55 US qt 0 46 Imp qt Differential gear oil Type Yamaha Friction Modified Plus 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...

Page 162: ...gear 23 14 28 23 2 000 Low range 31 16 1 938 High range 27 25 1 080 Chassis Frame type Steel tube frame Caster angle 4 53 Trail 26 0 mm 1 02 in Front tire Type Tubeless Size AT25 x 8 12 Manufacturer model CHENG SHIN C828 YFM70KDXJ_AUS NZL YFM70KPXJ_AUS NZL MAXXIS MU19 YFM70KDHJ YFM70KDXJ_EUR FRA GBR YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ_EUR FRA GBR Rear tire Type Tubeless Size AT25 x 10 12 Manuf...

Page 163: ...disc brake Operation Right hand operation Specified brake fluid DOT 4 Rear brake Type Mechanical wet multiple disc brake Operation Left hand and right foot operation Front suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 180 mm 7 1 in Rear suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 230 mm 9 1 in Elect...

Page 164: ...light LED Four wheel drive indicator light 12 V 1 7 W 1 YFM70KDHJ YFM70KDXJ Engine trouble warning light LED High range indicator light LED YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ Low range indicator light LED YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ Differential gear lock indicator light LED YFM70KPAJ YFM70KPHJ YFM70KPSJ YFM70KPXJ Fuses Main fuse 40 0 A Fuel injection system fuse 15 0 A EPS fuse 4...

Page 165: ...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 166: ...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 167: ...11 2 11 1 Model label 1 UB1662E0 book Page 2 Monday April 17 2017 11 39 AM ...

Page 168: ...fferential gear lock indicators YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPSJ 4 5 Differential gear oil 5 3 8 27 Drive lever 2WD 4WD YFM70KDXJ YFM70KDHJ 4 13 Drive select lever 4 16 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 9 Engine trouble warning light 4 3 EPS warning light for EPS model 4 4 F Final ...

Page 169: ...and tool kit 8 2 P Panels removing and installing 8 9 Park indicator light 4 2 Parking 6 4 Parking on a slope 6 5 Part locations 3 1 R Rear brake adjusting the lever pedal free play 8 45 Rear knuckle pivots lubricating 8 52 Reverse indicator light 4 2 Riding your ATV 7 1 S Safety information 2 1 Seat 4 19 Shock absorber assemblies adjusting the front and rear YFM70KPXJ YFM70KPAJ YFM70KPHJ YFM70KPS...

Page 170: ...charts 8 66 V Valve clearance 8 42 V belt case drain plug 8 40 Vehicle identification number 11 1 W Wheel hub bearings checking 8 51 Wheel installing 8 64 Wheel removing 8 64 UB1662E0 book Page 3 Monday April 17 2017 11 39 AM ...

Page 171: ...UB1662E0 book Page 4 Monday April 17 2017 11 39 AM ...

Page 172: ...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 ...