Yamaha GRIZZLY YFM70GDHG, Owner'S Manual

Page 1: ...EL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO 2UD F8199 60 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 2015 05 0 9 1 CR E F S ...

Page 3: ...important safety information WARNING OWNER S MANUAL YFM70GDXG YFM70GDHG YFM70GPXG YFM70GPHG YFM70GPSG YFM70GPLG This ATV should not be ridden by anyone under 16 years of age 2UD F8199 60 E0 U2UD60E0 book Page 1 Tuesday April 28 2015 11 55 AM ...

Page 4: ...Akihiro Tsuzuki Date of Issue If applicable and to the other relevant Directives of EEC 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 num...

Page 5: ... 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 Representative EC Decl...

Page 6: ...d basic understanding of the features and operation of this ATV This manual includes important safety information It provides information about special tech niques 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 R...

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 infor...

Page 8: ...heck your local riding laws and regulations before operating this ATV EBU17411 YFM70GDXG YFM70GDHG YFM70GPXG YFM70GPHG YFM70GPSG YFM70GPLG OWNER S MANUAL 2015 by Yamaha Motor Co Ltd 1st edition April 2015 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 U2UD60E0 book Page 1 Tuesday April 28 2015 11...

Page 9: ... pedal and rear brake lever 4 14 Drive select lever 4 15 Fuel tank cap 4 15 Fuel 4 16 Seat 4 17 Storage compartments 4 18 Front carrier 4 22 Rear carrier 4 22 Adjusting the front and rear shock absorber assemblies 4 22 Trailer hitch YFM70GPSG YFM70GPLG 4 23 Auxiliary DC jack 4 24 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Differential gear oil 5 3 Coolant 5 3 Front and rea...

Page 10: ...ission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing panels 8 10 Checking the spark plug 8 18 Engine oil and oil filter cartridge 8 21 Final gear oil 8 25 Differential gear oil 8 28 Coolant 8 30 Cleaning the air filter element 8 38 Cleaning the spark arrester 8 40 V belt case drain plug 8 42 Adjusting the throttle lever free play 8 42 Valve clearance 8 43...

Page 11: ...ting the steering shaft 8 53 Battery 8 54 Replacing a fuse 8 57 Replacing a headlight bulb 8 59 Adjusting a headlight beam 8 61 Tail brake light 8 62 Removing a wheel 8 62 Installing a wheel 8 62 Troubleshooting 8 64 Troubleshooting charts 8 65 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 INDEX 12 1 U2UD60E0 book Page 3...

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 U2UD60E0 book Page 1 Tuesday April 28 2015 11 55 AM ...

Page 13: ...1 2 1 For Europe 2 1 3 4 5 7 6 6 8 6 6 12 11 9 10 U2UD60E0 book Page 2 Tuesday April 28 2015 11 55 AM ...

Page 14: ...APAN YFM700FWAD 36 0 kW 314 kg 2015 2UD F155A 00 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWAD 36 0 kW 320 kg 2015 B31 F155A 00 B16 F817R 10 90 kg 198 lbs B16 F817R 00 50 kg 110 lbs 1P0 F816P 20 YAMAHA 1 YFM70GDXG YFM70GDHG 1 YFM70GPXG YFM70GPHG 1 YFM70GPSG YFM70GPLG 2 3 4 U2UD60E0 book Page 3 Tuesday April 28 2015 11 55 AM ...

Page 15: ...5880 N 600 kgf 1322 lbf 147 N 15 kgf 33 lbf 37S F817S 00 35 0 kPa 0 35 kgf cm 5 0 psi 30 0 kPa 0 30 kgf cm 4 4 psi 1HP F816M M0 YAMAHA 1HP F2259 21 5 7 6 8 U2UD60E0 book Page 4 Tuesday April 28 2015 11 55 AM ...

Page 16: ...1 5 1 1P0 F816R 00 YAMAHA YAMAHA 1HP F811R 00 10 9 U2UD60E0 book Page 5 Tuesday April 28 2015 11 55 AM ...

Page 17: ...1 6 1 B16 F816N 01 4 kg 9 lb 37S F816N 00 0 5 kg 1 lb 11 12 U2UD60E0 book Page 6 Tuesday April 28 2015 11 55 AM ...

Page 18: ...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 19: ...oss 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 rela...

Page 20: ...1 9 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 U2UD60E0 book Page 9 Tuesday April 28 2015 11 55 AM ...

Page 21: ...1 10 1 For Oceania 1 2 3 4 6 5 5 11 10 12 7 8 9 U2UD60E0 book Page 10 Tuesday April 28 2015 11 55 AM ...

Page 22: ... 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 U2UD60E0 book Page 11 Tuesday April 28 2015 11 55 AM ...

Page 23: ...ith cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Maximum Vehicle Load 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 ...

Page 24: ...COHOL NEVER operate ALWAYS 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 use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may ...

Page 25: ...RNING Storage should not exceed 4 kg 9 lbs B16 F151F 01 1 lb 0 5 kg 37S F151F 00 5ND F1558 00 Turning the ATV in 4WD LOCK DIFF LOCK takes more effort 10 11 12 U2UD60E0 book Page 14 Tuesday April 28 2015 11 55 AM ...

Page 26: ...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 27: ...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 28: ... as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are...

Page 29: ...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 30: ...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 31: ... 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 32: ...idge 8 Coolant reservoir 5 1 2 3 4 6 7 8 1 Rear storage compartment 2 Fuel tank cap 3 Owner s tool kit 4 Center storage compartment 5 Spark plug 6 Front shock absorber assembly spring preload adjusting ring 7 Brake pedal 8 V belt case drain plug 9 Rear shock absorber assembly spring preload adjusting ring 5 1 6 9 2 3 4 7 8 U2UD60E0 book Page 1 Tuesday April 28 2015 11 55 AM ...

Page 33: ...ver 3 Handlebar switches 4 Rear brake fluid reservoir 5 Horn switch 6 Multi function display 7 Front brake fluid reservoir 8 On Command four wheel drive differential gear lock switch 9 Throttle lever 10 Front brake lever 11 Front storage compartment 12 Main switch 13 Auxiliary DC jack 1 5 2 3 4 6 7 8 10 9 11 13 12 U2UD60E0 book Page 2 Tuesday April 28 2015 11 55 AM ...

Page 34: ...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 U2UD60E0 book Page 1 Tuesday April 28 2015 11 55 AM ...

Page 35: ...cator 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 On Command 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 Park indicator light P 7 On Command four ...

Page 36: ...s accumulated on the radiator i e after riding in wet terrain In this case have a Yamaha dealer clean the radiator Start the engine after making sure that the warning light is out Continuous use while the warning light is on may cause damage to the engine EBU30482 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is not work ing co...

Page 37: ...t the EPS motor from overheating EBU30451 On Command four wheel drive indicator On Command differential gear lock indicator and indicator light DIFF LOCK The On Command four wheel drive indicator comes on when the On Command four wheel drive switch is set to the 4WD position The On Command differential gear lock indicator and the On Command differential gear lock indicator light DIFF LOCK come on ...

Page 38: ...TRIP B in the fol lowing order ODO TRIP A TRIP B ODO To reset a tripmeter select it by pushing the SE LECT button and then push the RESET button for at least three seconds The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops TIP Pushing and holding in the SELECT button and turning the key to on ...

Page 39: ...CT button and then release it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter 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 This fuel meter is equipped with a self diagnosis system If the elec...

Page 40: ...on display indicates an error code note the code number and then 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 EBU18065 Handlebar switches 1 Error code display 2 Engine trouble warning light 1 2 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Ove...

Page 41: ...ht head lights high beams the center headlight 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 the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 54 EBU18171 Horn sw...

Page 42: ...istance for maneuvers All wheels turn at the same speed when the dif ferential is locked so it takes more effort to turn the ATV The effort needed to turn increas es 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 trav eling EBU26608 On Command four wheel drive switch 2WD 4WD WARNING EWB00164 Always stop the ATV before ch...

Page 43: ...WD position Then the four wheel drive indicator comes on in the multi function dis play To change from four wheel drive to two wheel drive stop the ATV and push the switch in to the 2WD position EBU30463 On Command differential gear lock switch 4WD LOCK WARNING EWB00132 Always stop the ATV before changing from four wheel drive to four wheel drive differen tial gear lock or vice versa The ATV handl...

Page 44: ...TV is equipped with a switch allowing you to lock the differential gear when in four wheel drive Select the appropriate switch position according to the terrain and the conditions 4WD four wheel drive Power is supplied to the rear and front wheels LOCK four wheel drive with the differential gear locked Power is supplied to the rear and front wheels and the differential gear is locked Unlike in fou...

Page 45: ...the switch to the 4WD position TIP When the switch is set to LOCK or 4WD the differential gear lock indicator and indicator light will flash until the differential gear is completely locked or unlocked When the indicator and indicator light are flash ing turning the handlebar back and forth will help the differential gear lock to engage or dis engage 1 Differential gear lock lever 2 On Command fou...

Page 46: ... the throttle le ver will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time the throttle lever is re leased Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever...

Page 47: ...peration You could lose control resulting in an accident EWB00242 3 Tighten the locknut EBU18392 Front brake lever The front brake lever is located on the right han dlebar To apply the front brake pull the brake le ver toward the handlebar 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...

Page 48: ...and park positions See the Operating the drive select lever and driving in reverse section on page 6 2 for the drive select lever operation EBU18721 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise 1 Brake pedal 1 Rear brake lever 1 1 1 Drive select lever 1 U2UD60E0 book Page 15 Tuesday April 28 2015 11 55 AM ...

Page 49: ...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 when it heats up heat from the engine or the sun can cau...

Page 50: ...00071 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoline with a 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...

Page 51: ...681 Storage compartments This ATV is equipped with three storage compart ments NOTICE ECB00831 Do not store metal or sharply edged objects like tools in the storage compartments If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartments 1 Seat 1 1 Projection 2 Seat holder 1 1 2 2 U2UD60E0 book Page 18 Tuesday April 28 2015 11 55 AM ...

Page 52: ...nt remove the storage compartment cover by turning it counterclockwise The center storage compartment is located in front of the seat To access the storage compart ment open the storage compartment lid 1 Front storage compartment cover 1 Front storage compartment U2UD60E0 book Page 19 Tuesday April 28 2015 11 55 AM ...

Page 53: ...ent open the storage compartment lid by turning the storage compartment knob 1 4 turn counterclock wise 1 Center storage compartment lid 1 Center storage compartment 1 1 1 Rear storage compartment lid 2 Rear storage compartment knob 3 Open 2 1 3 U2UD60E0 book Page 20 Tuesday April 28 2015 11 55 AM ...

Page 54: ...age compartment 4 0 kg 9 lb for the center storage compartment or 2 0 kg 4 lb for the rear storage compartment Do not exceed the maximum load of 240 0 kg 530 lb for the ATV TIP A drain plug is fitted at the bottom of each storage compartment If any water collects in a storage compartment remove the drain plug drain the water and then install the drain plug 1 Rear storage compartment 1 1 Front stor...

Page 55: ...or the ATV EBU19148 Adjusting the front and rear shock ab sorber assemblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions WARNING EWB00401 Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac cident 1 Center storage compartment d...

Page 56: ...appropriate notch in the adjusting ring with the position indicator on the shock absorber TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment EBU28972 Trailer hitch YFM70GPSG YFM70GPLG This ATV is equipped with a 5 cm 2 in trailer hitch receiver 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum...

Page 57: ...the engine is running and the light switch is set to OFF 1 Set the light switch to OFF 2 Turn the accessory off 3 Start the engine See page 6 1 4 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 5 Turn the accessory on 6 When the auxiliary DC jack is not being used cover it with the cap 1 Trailer hitch receiver 1 1 Auxiliary DC jack cap 2 Auxiliary DC jack Max...

Page 58: ... 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 automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged U2UD60E0 book Page 25 Tuesday April 28 2015 11 55 AM ...

Page 59: ... 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 16 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 21 Final gear oil Check ATV for oi...

Page 60: ...hrottle lever Make sure that operation is smooth Lubricate cable and lever housing if necessary Check lever free play and adjust if necessary 5 4 8 42 Control cables Make sure that operation is smooth Lubricate if necessary 8 50 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 p...

Page 61: ...ary See page 8 30 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU29083 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front and rear brake levers If there is free play have a Yamaha dealer check the brake system Check for correct free play in the brake pedal If the free play is incorrect adjust ...

Page 62: ...ust 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 must be equal on both sides WARNING Ope...

Page 63: ... 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 U2UD60E0 book Page ...

Page 64: ... tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination 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 1 Tire wear limit Front Manufacturer model MAXXIS MU05Y Size AT26 x...

Page 65: ...5 7 5 EBU19851 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary U2UD60E0 book Page 7 Tuesday April 28 2015 11 55 AM ...

Page 66: ...lant temperature warning light Engine trouble warning light The EPS warning light should come on then go off when the engine is started for EPS model NOTICE ECB00825 If a warning light does not go off see page 4 2 for the corresponding warning light circuit check To avoid possible damage do not oper ate the ATV if a warning light stays on 2 Apply the brake pedal and then shift the drive select lev...

Page 67: ...be as short as possible to preserve battery 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 EBU20442 Operating the drive select lever and driving in reverse NOTICE ECB00171 Before shifting stop the ATV otherwise the transmission may be damaged Shifting Neutral to High range and High range to L...

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 The drive select lever cannot be shifted into or from reverse or park without applying 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 ...

Page 69: ...n in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various pa...

Page 70: ...e engine and shift the drive select lever into the park position EBU29901 Parking on a slope WARNING EWB00861 Avoid parking on hills or other inclines Parking on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident If you must park on an incline place the ATV transversely across the incline stop the engine shift the drive select lever to the park ...

Page 71: ...aftermarket products similar in design and quality to genuine Yamaha Accesso ries recognize that some aftermarket accessories or modifications are not suitable because of po tential safety hazards to you or others Installing aftermarket products or having other modifica tions performed to your ATV that change any of the vehicle s design or operation characteristics can put you and others at greate...

Page 72: ...or pulling a trailer Allow greater dis tance for braking Cargo or a trailer can change the stability and han dling of an ATV You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable MAXIMUM LOADING LIMIT ATV loading limit total weight of rider car go accessories and ...

Page 73: ...down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load 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 ...

Page 74: ...7 1 7 EBU21142 RIDING YOUR ATV U2UD60E0 book Page 1 Tuesday April 28 2015 11 55 AM ...

Page 75: ... 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 o...

Page 76: ...t 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 control...

Page 77: ... 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 wit...

Page 78: ...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 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 t...

Page 80: ...uld cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident EWB01472 MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rid er accessories and tongue 240 0 kg 530 lb Front carrier 50 0 kg 110 lb Rear carrier 90 0 kg 198 lb Front storage compartmen...

Page 81: ...installa tion or use of accessories or other modification All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be in stalled and used according to instructions If you have questions consult an authorized ATV dealer WARNING Operating this ATV with improper modifications may cause changes in handling which in some situa...

Page 82: ...it The muffler and other engine parts become ex tremely hot during operation and remain hot after the engine has stopped To reduce the risk of fire during operation or after leaving the ATV do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to other hot parts Check under the vehicle after operating in areas where combustible mate rials may...

Page 83: ...ther vehicles Make sure you know your country s laws and regulations before you ride on unpaved public streets or roads Do not ride on any paved public street road or motor way WARNING Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle EWB01522 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots...

Page 84: ... on excessively rough slippery or loose terrain could cause loss of traction or ATV con trol which could result in an accident includ ing an overturn EWB01542 When riding in an area where you might not easily be seen such as desert terrain mount a caution 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 y...

Page 85: ...in riding your ATV With the engine idling shift the drive select lever into the low range position or the high range position Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds until you are thoroughl...

Page 86: ...the ATV will resist turning A special turning tech nique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed As you approach a curve slow down and begin to turn the handlebars in the desired direction As you do so put your weight on the footboard to the outside of the turn opposite your desired direc tion and lean your upper ...

Page 87: ...UPHILL WARNING EWB01672 Climbing hills improperly can cause overturns or loss of control Use proper riding techniques described in this Owner s Manual Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Always check the terrain carefully before you start up any hill Never climb hi...

Page 88: ...momentum but not so fast that you cannot react to changes in the terrain as you climb It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steeper inclines standing on the footboards and leaning forward over the handlebars When ever possible ride straight up hills Slow down when you reach the crest o...

Page 89: ...re inter connected by the drive train applying either brake will brake all wheels therefore avoid sudden ap plication of either the front or rear brake as the wheels on the uphill side could come off the ground The ATV could easily tip over backwards Apply both the front and rear brakes gradually When fully stopped lock shift to the park position and dismount the ATV immediately on the uphill side...

Page 90: ...r maximum engine com pression braking effect select the low range posi tion and change to 4WD before beginning to descend the hill Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the d...

Page 91: ...equires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose...

Page 92: ... risk of an overturn The ATV can be used to cross slow moving shal low water of up to a maximum of 35 cm 14 in in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and carefully Test your brakes after leaving the water If neces sary apply them several times to let ...

Page 93: ...of the air filter case Also remove the drain plugs from the storage compartments and the V belt case to drain any water that may have accu mulated NOTICE Undrained water can cause damage or improper operation ECB00842 Wash the ATV in fresh water if it has been operat ed in salt water or muddy conditions 1 Air filter case check hose 1 Front storage compartment drain plug 1 U2UD60E0 book Page 20 Tue...

Page 94: ...as large 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 Center storage compartment drain plug 1 Rear storage compartment drain plug 1 1 1 V belt case drain plug 1 U2UD60E0 book Page 21 Tu...

Page 95: ...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 96: ...Position your weight over the front wheels for better control See page 7 13 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 13 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 recomme...

Page 97: ...you discover that the ATV is going to tip over dismount on the uphill side See page 7 18 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 98: ...n 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 Br...

Page 99: ...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 100: ...l 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 clearance and adjust if necessa...

Page 101: ...eed 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 U2UD60E0 book Page 4 Tuesday April 28 2015 11 55 AM ...

Page 102: ... with an asterisk should be performed by a Yamaha 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 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check ...

Page 103: ...nd replace if nec essary 7 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 8 Wheel hub bearings Check for looseness or damage and replace if necessary 9 V belt Check for wear cracks or other damage and re place if necessary 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened NO ITEM CHECK OR MA...

Page 104: ... Check toe in and adjust if necessary 16 Engine mount Check for cracks or other damage and replace if necessary 17 Axle boots Check for cracks or other damage and replace if necessary 18 Engine oil Change Check ATV for oil leakage 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 NO ITEM CHECK OR MA...

Page 105: ...ace if neces sary 25 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 26 Front and rear brake switches Check operation and correct if necessary 27 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 ...

Page 106: ... full throttle Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U2UD60E0 book Page 9 Tuesday April 28 2015 11 55 AM ...

Page 107: ...ance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU34720 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 U2UD60E0 book Page 10 Tuesday April 28 2015 11 55 AM ...

Page 108: ...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 U2UD60E0 book Page 11 Tuesday April 28 2015 11 55 AM ...

Page 109: ...l the panel upward 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 3 Projection 3 3 1 2 3 2 U2UD60E0 book Page 12 Tuesday April 28 2015 11 55 AM ...

Page 110: ... 1 Remove the seat See page 4 17 2 Remove panel A 3 Remove the hoses from panel C 4 Remove the quick fasteners and bolts Tightening torques Carrier bolt upper 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt lower 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Hose 1 1 U2UD60E0 book Page 13 Tuesday April 28 2015 11 55 AM ...

Page 111: ...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 2 1 Screw 1 1 U2UD60E0 book Page 14 Tuesday April 28 2015 11 55 AM ...

Page 112: ...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 U2UD60E0 book Page 15 Tuesday April 28 2015 11 55 AM ...

Page 113: ...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 U2UD60E0 book Page 16 Tuesday April 28 2015 11 55 AM ...

Page 114: ...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 U2UD60E0 book Page 17 Tuesday April 28 2015 11 55 AM ...

Page 115: ...ance 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 10 2 Remove the storage compartment by remov ing the bolt 3 Remove the spark plug cap Tightening torques Panel bolt 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard nut 4 0 Nm 0 40 m kgf 2 9 ft lbf 1 Storage compartment 2 Bolt 1 Spark plug...

Page 116: ...lug 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 S...

Page 117: ...vailable 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 Spark...

Page 118: ...el 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 A...

Page 119: ... 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 min utes 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 120: ...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 U2UD60E0 book Page 23 Tuesday April 28 2015 11 55 AM ...

Page 121: ...rque 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 Nm 1 5 m kgf 11 ft lbf Tightening torque Engine oil drain bolt 22 Nm 2 2 m kgf 16 ft lbf 1 U2UD60E0 book Page 24 Tuesday April 28 2015 11 55 AM ...

Page 122: ... 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 repai...

Page 123: ...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 Nm...

Page 124: ...n 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 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil 2 Gasket 3 Final gear oil level check bo...

Page 125: ...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 o...

Page 126: ...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 Nm 2 3 m kgf 17 ft lbf 1 Differential gear oil drain bolt 2 Gasket 1 2 Tightening torque D...

Page 127: ...ervals 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 See...

Page 128: ...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 129: ...r 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 10 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 U2UD60E0 book Page 32 Tuesday April 28 2015 11 55 AM ...

Page 130: ... 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 U2UD60E0 book Page 33 Tuesday April 28 2015 11 55 AM ...

Page 131: ...e 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 wate...

Page 132: ...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 133: ...s 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 bo...

Page 134: ...ls 1 Footboard nut 2 Footboard bolt A 3 Footboard bolt B 3 1 2 1 Tightening torques Footboard nut 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard bolt A 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard bolt B 8 Nm 0 8 m kgf 5 8 ft lbf 4 1 2 3 U2UD60E0 book Page 37 Tuesday April 28 2015 11 55 AM ...

Page 135: ...heck 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 17 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 fi...

Page 136: ...nge 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 U2UD60E0 ...

Page 137: ...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 perfo...

Page 138: ... 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 Nm 1 0 m kgf 7 2 ft lbf 3 2 1 U2UD60E0 book Page 4...

Page 139: ... 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 m...

Page 140: ...t EBU24072 Adjusting the drive select lever safety system cable The drive select lever safety system cable stretch es with use which can result in improper function Therefore the safety system cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EBU29602 Brakes Replacement of brake components requires pro fessional kno...

Page 141: ...or groove which allows you to check the brake pad wear without having to disassemble the brake If a brake pad has worn to the point that the wear in dicator groove has almost disappeared 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 62 Front brake Rear brake 1 Wear indicator groove 1 Wear indicator groove U2UD60E0 book Pag...

Page 142: ...ake Rear brake WARNING EWB02721 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may allow air to enter the brake system reducing braking perfor mance Clean the filler cap before removing Use only DOT 4 brake fluid from a sealed contain er 1 Minimum level mark 2WD 4WD 1 1 Minimum level mark Specified brake fluid DOT 4 U2UD60E0 book Page ...

Page 143: ...ds for wear and the brake system for leakage If the brake fluid level goes down sud denly have a Yamaha dealer check the cause be fore further riding EBU24293 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrication chart In addition have the oil seals of the master cylinders and calipers as well as the brake hoses ...

Page 144: ... perform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting the brake pedal free play check the rear brake pads for wear The brake pedal free play should measure 1 0 6 0 mm 0 04 0 24 in as shown If the free play is in correct adjust it as follows 1 No brake lever free play 1 No brake lever free play 1 U2UD60E0 book Page 47 Tuesday April 28 2015 11...

Page 145: ...rease the free play and in direction b to decrease it 4 Tighten the locknut 5 After adjusting there should be slight play at the brake pedal cable joint as shown If there is no play repeat steps 2 to 4 1 Brake pedal free play 1 1 Locknut 2 Brake pedal free play adjusting nut U2UD60E0 book Page 48 Tuesday April 28 2015 11 55 AM ...

Page 146: ...d brake pedal do not move EBU24231 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them replaced by a Yamaha dealer 1 Brake pedal cable joint 2 Slight play 0 1 0 5 mm 0 004 0 02 in 1 2 1 Front axle boot each side 1 1 U2UD60E0 book Page 49 Tuesday Ap...

Page 147: ...operation 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 EBU24913 Checking and lubricating the front and rear brake levers The operation of the front and rear brake lever...

Page 148: ...al The operation of the brake pedal should be checked 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 10 Recommended lubricant Lithium soap based grease U2UD60E0 book Page 51 Tuesday April 28 2015 11 55 AM ...

Page 149: ...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 EBU25053 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with...

Page 150: ...intervals specified in the pe riodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun YFM70GDXG YFM70GDHG YFM70GPXG YFM70GPHG YFM70GPSG YFM70GPLG 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 U2UD60E0 book Page 53 Tuesday April 28 2015 11 55 AM ...

Page 151: ...te 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 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 REA...

Page 152: ...CB01002 5 Pull the battery out of its compartment To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional elec trical accessories 1 Carrier bolt under the fenders 2 Carrier bolt lower 1 2 2 1 1 Battery holding plate 2 Nut 3 Negative battery lea...

Page 153: ...ery charged Storing a discharged battery can cause permanent bat tery damage To install the battery TIP Be sure the battery is fully charged 1 Place the battery in its compartment 2 Connect the positive battery lead first then connect the negative battery lead 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...

Page 154: ... 3 4 m kgf 25 ft lbf Carrier bolt lower 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 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 U2UD60E0 book Page 57 Tuesday April 28 2015 11 55 AM ...

Page 155: ... fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Always use a fuse of the spec ified rating and never use a substitute ob ject in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical system which could lead to a fire EWB02173 1 Headlight fuse 2 Signaling system fuse 3 Radiator fan motor fuse 4 Ignition fuse 5...

Page 156: ...ove the headlight cover by removing the quick fasteners 2 Remove the headlight bulb holder cover by pulling it off Specified fuses Main fuse 40 0 A Headlight fuse 10 0 A Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A Signaling system fuse 10 0 A Auxiliary DC jack fuse 10 0 A Radiator fan motor fuse 20 0 A Fuel injection system fuse 15 0 A EPS fuse 40 0 A YFM70GPHG YFM70GPLG YFM70GPSG YFM7...

Page 157: ...e the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the head light bulb using a cloth moistened with al cohol or thinner ECB00652 6 Install the bulb holder by pushing it in and turning it clockwise 1 Headlight bulb holder cover 1 Headlight bulb holder 1 1 1 Do not touch the glass part of the bulb ...

Page 158: ...equipped with LED type headlights for the left and right headlights If the left or right headlight does not come on have a Yamaha dealer check it EBU25553 Adjusting 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 direct...

Page 159: ...2 Loosen the wheel nuts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU25702 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP The arrow mark on the tire must point to ward the rotating direction of the wheel 1 Headlight beam adjusting screw b a 1 1 Wheel nut 1 1 U2UD60E0 book Page 62 Tues...

Page 160: ...apered side towards the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf 1 U2UD60E0 book Page 63 Tuesday April 28 2015 11 55 AM ...

Page 161: ...ny repair take it 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 ...

Page 162: ... 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 quic...

Page 163: ... 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 164: ...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 165: ...he 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 f...

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 54 TIP Make any necessary repairs before storing the ATV U2UD60E0 book Page 3 Tuesday April 28 2015 11 55 AM ...

Page 167: ... r min EUR Uncertainty of measurement 3 0 dB A EUR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s EUR Uncertainty of measurement 0 0 m s YFM70GPHG_EUR YFM70GPLG YFM70GPSG_EUR YFM70GPXG_EUR 0 1 m s YFM70GDHG YFM70GDXG Vibration on handle EN1032 ISO5008 Will not exceed 2 5 m s EUR Uncertainty of measurement 0 3 m s EUR Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Sin...

Page 168: ...ntity 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 L 4 75 US gal 3 96 Imp gal Fuel reserve amount 4 L 1 06 US gal 0 88 Imp gal Fuel injection Throttle body ID mark B161 00 Spark plug s Manufa...

Page 169: ...turer model MAXXIS MU05Y Rear tire Type Tubeless Size AT26 x 10 12 Manufacturer model MAXXIS MU06Y Loading Maximum loading limit 240 0 kg 530 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi F...

Page 170: ...pring gas oil damper Wheel travel 193 mm 7 6 in Rear suspension Type Double wishbone Spring shock absorber type Coil spring gas oil damper Wheel travel 232 mm 9 2 in Electrical system Ignition system TCI Charging system AC magneto Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Headlight High mounted headlight bulb type Halogen bulb Bulb voltage wattage quantity Headlight LED High mounted he...

Page 171: ...30402 For Europe only The figures quoted are emission levels and are not necessarily safe working levels Whilst there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required Factors that influence the actual level of exposure of work force include the characteristics of the work room the other sources of no...

Page 172: ... 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 Yama...

Page 173: ...11 2 11 1 Model label 1 U2UD60E0 book Page 2 Tuesday April 28 2015 11 55 AM ...

Page 174: ...oil 5 3 8 28 Drive select lever 4 15 Drive select lever and driving in reverse 6 2 Drive select lever safety system cable adjusting 8 43 E Engine break in 6 4 Engine oil 5 3 Engine oil and oil filter cartridge 8 21 Engine stop switch 4 8 Engine trouble warning light 4 3 EPS warning light for EPS model 4 4 F Final gear oil 5 3 8 25 Four wheel drive differential gear lock indicator 4 4 Front and rea...

Page 175: ... Safety information 2 1 Seat 4 17 Shock absorber assemblies adjusting the front and rear 4 22 Spark arrester cleaning 8 40 Spark plug checking 8 18 Specifications 10 1 Speed limiter 4 13 Stabilizer bushes checking 8 52 Starting the engine 6 1 Start switch 4 8 Steering shaft lubricating 8 53 Storage 9 2 Storage compartments 4 18 T Tail brake light 8 62 Throttle lever 4 13 5 4 Throttle lever free pl...

Page 176: ...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 ...