Grizzly 660 - Yamaha Motor Company · LIT-11626-16-34 5KM-28199-11 READ THIS MANUAL CAREFULLY! It contains important safety information. WARNING This ATV should not be ridden by anyone

5KM-28199-11LIT-11626-16-34

READ THIS MANUAL CAREFULLY!It contains important safety information.

This ATV should not be ridden by anyone under 16 years of age.WARNING

YFM660FR

OWNER’S MANUAL

PRINTED IN JAPAN2002.06-7.8×1 CR

(E)

PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.

EBU00438

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.(For replacement manual, call 1-800-532-1558)

WARNING

ALWAYS: 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.

Improper ATV use can result in SEVERE INJURY or DEATH.

NEVER operate: without proper training or instruction. at speeds too fast for your skills or the conditions. on public roads-a collision can occur with another vehicle. with a passenger-passengers affect balance and steering and increase risk of losing control.

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

B EE R

B EE R

EBU00776

EBU00941

1-INTRODUCTION

Congratulations on your purchase of the Yamaha YFM660F. It represents the result of manyyears of Yamaha experience in the production of fine sporting, touring, and pace-setting racingmachines. With the purchase of this Yamaha, you can now appreciate the high degree of crafts-manship and reliability that have made Yamaha a leader in these fields.This manual will provide you with a good basic understanding of the features and operation of thisATV. This manual includes important safety information. It provides information aboutspecial techniques and skills necessary to ride your ATV. It also includes basic maintenanceand inspection procedures. If you have any questions regarding the operation or maintenance ofyour ATV, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:� READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND

COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALLINSTRUCTIONS.

� PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.� NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE

TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887FOR MORE INFORMATION.

� THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONEUNDER 16 YEARS OF AGE.

U5KM11.book Page 1 Thursday, June 27, 2002 3:58 PM

EBU00801

ON

ANUAL CAN RESULT IN

following notations:

ION! BECOME ALERT!

could result in severe bystander or a person

that must be taken to

cedures easier or clearer.


1-IMPORTANT MANUAL INFORMATI

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MSERIOUS INJURY OR DEATH.Particularly important information is distinguished in this manual by the

The Safety Alert Symbol means ATTENTYOUR SAFETY IS INVOLVED!

WARNING Failure to follow WARNING instructions injury or death to the machine operator, ainspecting or repairing the machine.

CAUTION: A CAUTION indicates special precautionsavoid damage to the machine.

NOTE: A NOTE provides key information to make pro

nly. It is illegal and unsafe to

and spark arrester laws and

g this machine.

YFM660FRER’S MANUALaha Motor Corporation,

U.S.A.dition, May 2002ights reserved.

Any reprinting or unauthorized usewithout the written permission

of Yamaha Motor Corporation, U.S.A.is expressly prohibited.

Printed in Japan.P/N LIT-11626-16-34


AFFIX DEAL

LABEL HER

EBU00011

This machine is designed operate this machine on anThis machine complies witregulations in effect at the Please check your local rid

EBU00981

ER

E

IMPORTANT NOTICE

and manufactured for OFF-ROAD use oy public street, road or highway.h all applicable OFF-ROAD noise level time of manufacture.ing laws and regulations before operatin

OWN©2002 by Yam

1st eAll r

EBU00014

Key identificationVehicle identificaModel label .........

NCTIONS...................4-1.....................................4-1 warning lights.............4-2r unit ............................4-5.....................................4-6itches .........................4-7

r ..................................4-12r ..................................4-13ever............................4-14edal and lever ...........4-14

lever ...........................4-15r..................................4-16p .................................4-17...................................4-18e) ..............................4-19...................................4-20

Storage compartment ....................4-21...................................4-21...................................4-21ar shock absorber ...................................4-22 jack............................4-24


number................ 3-2tion number .......... 3-3............................. 3-3

Front carrierRear carrier .Front and readjustment

Auxiliary DC

WARNINGIndicates a potential hazard that couldresult in serious injury or death.

CONTENTS

LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1

SAFETY INFORMATION.................. 2-1

DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1Identification number records.......... 3-2

1

2

3

CONTROL FUMain switch .Indicator andSpeedometeFuel gauge ..Handlebar swThrottle leveSpeed limiteFront brake lRear brake pDrive select Recoil starteFuel tank caFuel cock.....Starter (chokSeat.............

4

k-in ...............................6-7......................................6-8 slope...........................6-9 and loading ...............6-10

R ATV..........................7-1now your ATV ...............7-3re and good ......................................7-4here you ride..............7-16r ATV ..........................7-22hill ...............................7-24hill ..............................7-30lope............................7-32ough shallow water ....7-34rough terrain...............7-37skidding.......................7-38if...................................7-40....................................7-40


PRE-OPERATION CHECKS ........... 5-1Front and rear brakes ..................... 5-2Fuel ................................................. 5-4Engine oil ........................................ 5-6Final gear oil.................................... 5-7Differential gear oil .......................... 5-7Coolant............................................ 5-7Throttle lever ................................... 5-9Fittings and Fasteners .................... 5-9Lights............................................... 5-9Switches.......................................... 5-9Tires .............................................. 5-10How to measure tire pressure....... 5-12Tire wear limit................................ 5-13

OPERATION..................................... 6-1Starting a cold engine ..................... 6-1Starting a warm engine................... 6-3Warming up..................................... 6-3Drive select lever operation and reverse driving............................... 6-4

Engine breaParking.......Parking on aAccessories

RIDING YOUGetting to kRide with cajudgement

Be careful wTurning youClimbing upRiding downCrossing a sCrossing thrRiding over Sliding and What to do What to do .

5

6

7

djustment..................8-39ever and pedal ...................................8-40 rear brake light ...................................8-42tion and lubrication....8-43nd brake pedal ...................................8-43pper and lower

rication .......................8-44al...............................8-45ation...........................8-45...................................8-47tenance......................8-48ment ..........................8-49headlight bulb ............8-51am adjustment...........8-52ht bulb t .................................8-53ting .............................8-54ting charts ..................8-55


PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1Owner’s manual and tool kit............ 8-1Periodic maintenance/lubrication .... 8-3Panel removal and installation ........ 8-5Engine oil....................................... 8-12Final gear oil .................................. 8-16Differential gear oil......................... 8-18Cooling system.............................. 8-20Axle boots...................................... 8-25Spark plug inspection.................... 8-26Air filter element cleaning.............. 8-29Spark arrester cleaning ................. 8-32V-belt cooling duct check hose ..... 8-33Carburetor adjustment................... 8-34Idle speed adjustment ................... 8-35Valve clearance adjustment.......... 8-35Throttle lever adjustment............... 8-36Front brake pad inspection............ 8-36Rear brake pad inspection ............ 8-37Inspecting the brake fluid level...... 8-37Brake fluid replacement................. 8-39

Front brake aRear brake ladjustment

Adjusting theswitch ........

Cable inspecBrake lever alubrication..

Rear wheel uknuckle lub

Wheel removWheel installBattery.........Battery mainFuse replaceReplacing a Headlight beTail/brake ligreplacemen

TroubleshooTroubleshoo

8


CLEANING AND STORAGE............ 9-1A. Cleaning...................................... 9-1B. Storage ....................................... 9-3

SPECIFICATIONS.......................... 10-1

NOISE REGULATION.................... 11-1

MAINTENANCE RECORD ............ 12-1

ATV LIMITED WARRANTY ........... 13-1

YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................... 14-1

9

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14

EBU00464

D


1-1

LOCATION OF THE WARNING ANSPECIFICATION LABELS

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14

5390 N (550 kgf)1212 lbf

147 N ( 15 kgf)33 lbf

5KM-2151K-00

DING LIMIT

WARNINGNEVER sit here.

3MX-24875-A0

2

E-1.fm Page 2 Thursday, June 27, 2002 4:45 PM

1-2

TONGUE WEIGHT:

Read and understand all of the labels on yourmachine. They contain important informationfor safe and proper operation of your ATV.

Never remove any labels from your ATV. If alabel becomes difficult to read or comes off, areplacement label is available from yourYamaha dealer.

85 kg {187 lbs}

4WV-24877-A0

LOAD LIMIT

PULLING LOAD:MAXIMUM LOA

4

1

3


1-3

5 6

7

R

NING

7-01

TV if you are

ou are unders your chanceth.

RNINGWD-LOCK(“DIFF. LOCK”)

peed and allownce for maneuversrol.

5KM-21558-00


1-4

8 9

0

UNDE

WAR

5FE-2169

NEVER operate this Aunder age 16.

Operating this ATV if ythe age of 16 increaseof severe injury or dea

WATurning the ATV in 4takes more effort.

Operate at a slow sextra time and distato avoid loss of cont

EBU01129

An ATV handles differentlyer can occur quickly, evenbstacles, if you fail to take

tructions: rocedures described. Training Course. Begin-thorized ATV dealer or call

ne size greater than 90cc. pervision, and never allowbilities to operate it safely.

idewalks, driveways, park-

a dirt or gravel one.


2-1

SAFETY INFORMATION

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. from other vehicles including motorcycles and cars. A collision or rollovduring routine maneuvers such as turning and riding on hills or over oproper precautions. SEVERE INJURY OR DEATH can result if you do not follow these ins� Read this manual and all labels carefully and follow the operating p� Never operate an ATV without proper training or instruction. Take a

ners should receive training from a certified instructor. Contact an au1-800-887-2887 to find out about the training courses nearest you.

� Always follow the age recommendation: - A child under 16 years old should never operate an ATV with engi

� Never allow a child under age 16 to operate an ATV without adult sucontinued use of an ATV by a child if he or she does not have the a

� Never carry passenger on an ATV. � Always avoid operating an ATV on any paved surfaces, including s

ing lots and streets. � Never operate an ATV on any public street, road or highway, even

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lmet that fits properly. Youboots, long-sleeved shirt or

. lways go at a speed that isxperience.

afe operating condition. Al-ules described in this man-

otboards of the ATV during

r terrain. Always be alert to

ou have learned and prac-s be especially cautious on

nual. Practice turning at lowxcessive speed. bilities. Practice on smaller


2-2

� Never operate an ATV without wearing an approved motorcycle heshould also wear eye protection (goggles or face shield), gloves, jacket, and long pants.

� Never consume alcohol or drugs before or while operating this ATV� Never operate at speeds too fast for your skills or the conditions. A

proper for the terrain, visibility and operating conditions, and your e� Never attempt wheelies, jumps, or other stunts. � Always inspect your ATV each time you use it to make sure it is in s

ways follow the inspection and maintenance procedures and schedual.

� Always keep both hands on the handlebars and both feet on the fooperation.

� Always go slowly and be extra careful when operating on unfamiliachanging terrain conditions when operating the ATV.

� Never operate on excessively rough, slippery or loose terrain until yticed the skills necessary to control the ATV on such terrain. Alwaythese kinds of terrain.

� Always follow proper procedures for turning as described in this maspeeds before attempting to turn at faster speeds. Do not turn at e

� Never operate the ATV on hills too steep for the ATV or for your ahills before attempting larger hills.

his manual. Check the ter-cessively slippery or loosey. Never go over the top of

ng on hills as described inill. Shift your weight back-

an angle that would causere possible.

described in this manual.ight to the uphill side of theave mastered the turning

g the side of a steep hill if

mbing a hill. To avoid stall-ing a hill. If you stall or roll manual. Dismount on the

and remount, following the


2-3

� Always follow proper procedures for climbing hills as described in train carefully before you start up any hill. Never climb hills with exsurfaces. Shift your weight forward. Never open the throttle suddenla hill at high speed.

� Always follow proper procedures for going down hills and for brakithis manual. Check the terrain carefully before you start down any hward. Never go down a hill at high speed. Avoid going down a hill atthe vehicle to lean sharply to one side. Go straight down the hill whe

� Always follow proper procedures for crossing the side of a hill asAvoid hills with excessively slippery or loose surfaces. Shift your weATV. Never attempt to turn the ATV around on any hill until you htechnique described in this manual on level ground. Avoid crossinpossible.

� Always use proper procedures if you stall or roll backwards when cliing, use proper gear range and maintain a steady speed when climbbackwards, follow the special procedure for braking described in thisuphill side or to a side if pointed straight uphill. Turn the ATV around procedure described in this manual.

er attempt to operate overroper procedures when op-

skidding or sliding by prac-pery surfaces, such as ice,idding or sliding out of con-

n that recommended in thisility. Test your brakes after

dry out the linings. en you operate in reverse.

sories. be properly distributed andanual for carrying cargo or

mer Products Safety Com- 1-800-852-5344.


2-4

� Always check for obstacles before operating in a new area. Nevlarge obstacles, such as large rocks or fallen trees. Always follow perating over obstacles as described in this manual.

� Always be careful when skidding or sliding. Learn to safely controlticing at low speeds and on level, smooth terrain. On extremely slipgo slowly and be very cautious in order to reduce the chance of sktrol.

� Never operate an ATV in fast flowing water or in water deeper thamanual. Remember that wet brakes may have reduced stopping ableaving water. If necessary, apply them several times to let friction

� Always be sure there are no obstacles or people behind you whWhen it is safe to proceed in reverse, go slowly.

� Always use the size and type tires specified in this manual. � Always maintain proper tire pressure as described in this manual. � Never modify an ATV through improper installation or use of acces� Never exceed the stated load capacity for an ATV. Cargo should

securely attached. Reduce speed and follow instructions in this mpulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at

ng the ATV in another it is kept upright andk is in the “OFF” posi-fuel may leak out of thel tank. PEN onous and can cause

THE HAZARD allow some gasoline orgasoline vapor, or getn your eyes, see yourely. If gasoline spills onwith soap and water. If your clothing, change


2-5

WARNING

POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you couldbe burned. HOW TO AVOID THE HAZARD Always turn off the engine when refuel-ing. Do not refuel right after the enginehas been running and is still very hot.Do not spill gasoline on the engine orexhaust pipe/muffler when refueling.Never refuel while smoking, or while inthe vicinity of sparks, open flames, orother sources of ignition such as the pi-lot lights of water heaters and clothesdryers.

When transportivehicle, be surethat the fuel coction. Otherwise, carburetor or fueWHAT CAN HAPGasoline is poisinjuries. HOW TO AVOID If you should swinhale a lot of some gasoline idoctor immediatyour skin, wash gasoline spills onyour clothes.

WARNING

ZARD ning the engine in a

PEN are poisonous and maynsciousness and deathe.

THE HAZARD your ATV in an area withtion.


2-6

POTENTIAL HAStarting or runclosed area. WHAT CAN HAPExhaust fumes cause loss of cowithin a short timHOW TO AVOIDAlways operate adequate ventila

EBU00032

ICATION

g

tool kit

ng

9. Radiator cap

15. Engine oil dipstick16. Recoil starter17. Coolant reservoir18. Drive select lever box check hose 19. V-belt cooling duct check hose20. Rear brake lever21. Left handlebar switches22. Starter (choke)23. Speedometer unit24. Main switch25. Right handlebar switches26. Throttle lever27. Front brake lever28. Auxiliary DC jack

have purchased may differ slightlyin the figures of this manual.


3-1

10. Drive select lever11. Fuel tank cap12. Fuel cock13. Fuses14. Battery

NOTE:The machine you from those shown

DESCRIPTION

1. Rear shocpreload ad

2. Storage co3. Air filter ca4. Front brak5. Front shoc

preload ad6. Rear brake7. Rear brake8. V-belt case

AND MACHINE ID
ENTIF
k absorber sprinjusting ringmpartment andsee fluid reservoirk absorber sprijusting ring fluid reservoir pedal drain plug

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numberion number is stamped onin the following illustration.e used for ordering a new

ber


3-2

EBU00600

Identification number recordsRecord the key identification number, vehicleidentification number and model label infor-mation in the spaces provided for assistancewhen ordering spare parts from a Yamahadealer or for reference in case the vehicle isstolen.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUMBER:

3. MODEL LABEL INFORMATION:

EBU00035

Key identificationThe key identificatthe key as shown This number can bkey.

1. Key identification num

EBU00036 EBU00787

ffixed to the location in thethe information on this la-vided. This information willer spare parts from your


3-3

Vehicle identification numberThe vehicle identification number is stampedinto the frame.

1. Vehicle identification number

NOTE:The vehicle identification number is used toidentify your machine.

Model labelThe model label is aillustration. Record bel in the space probe needed to ordYamaha dealer.

1. Model label

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14


4-1

EBU00039

CONTROL FUNCTIONS


EBU00942

Main switchFunctions of the respective switch positionsare as follows: ON: The engine can be started only at this positionand the headlights and taillight come on whenthe light switch is on. OFF: All electrical circuits are switched off. The keycan be removed in this position.

1. Main switch

EBU00802 EBU01130

ck indicator light “DIFF.

comes on along with thek indicator in the displayl gear lock switch is set toosition.

or light “L” comes on when the drive “L” position.

tor light “H” comes on when the drive “H” position.

ight “N” comes on when the drive “N” position.


4-2

Indicator and warning lights

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. Park indicator light “P”7. Four-wheel-drive indicator “ ”/“ ”8. Coolant temperature warning light “ ”

Differential gear loLOCK” This indicator light differential gear locwhen the differentiathe “LOCK-4WD” p

EBU01122

Low-range indicatThis indicator light select lever is in the

EBU01064

High-range indicaThis indicator light select lever is in the

EBU00972

Neutral indicator lThis indicator light select lever is in the

DIFF.LOCK

indicator “ ”/“ ” es on when the “2WD”/

t to the “4WD” position. Theicator “DIFF.LOCK” in the

indicator also comes on“4WD” switch is set to thetion.

ronizing mechanism in these, the four-wheel drive in-me on until the ATV starts

DIFF.LOCK


4-3

EBU00867

Reverse indicator light “R”This indicator light comes on when the driveselect lever is in the “R” reverse position.

NOTE:If the indicator light flashes or the speedome-ter does not show the speed while riding,have a Yamaha dealer check the speed sen-sor circuit. _

EBU00609

Park indicator light “P”This indicator light comes on when the driveselect lever is in the “P” (park) position.

EBU01131

Four-wheel-driveThis indicator com“4WD” switch is sedifferential lock indfour-wheel-drive when the “LOCK”-“LOCK-4WD” posi

NOTE:_

Due to the synchdifferential gear cadicator may not comoving. _

EBU00860


4-4

Coolant temperature warning light “ ”When the coolant temperature reaches aspecified level, this light comes on to warnthat the coolant temperature is too hot. If thelight comes on during operation, stop the en-gine as soon as it is safe to do so and allowthe engine to cool down for about 10 minutes.

CAUTION:_

� The engine may overheat if the ATV isoverloaded. If this happens, reducethe load to specification.

� After restarting, make sure that thelight is out. Continuous use while thelight is on may cause damage to theengine.

_

which shows the total timen turned to “ON”)

pmeter modes/ODO” button switches thehe odometer mode “ODO”odes “A” and “B” in the fol-

RIP B→ODOer, select it by pushing then, and then push the “TRIP/t least three seconds. The used to estimate the dis-raveled with a full tank of fu-n will enable you to plan

IP/ODO” button and then “ON” switches the displayd “km/h”.


4-5

EBU01132

Speedometer unit

1. Speedometer 2. Odometer/Tripmeter A/Tripmeter B3. Clock/Hour meter 4. TRIP/ODO button5. Clock/Hour “ ”/“ ” button6. “H” button 7. “M” button

The speedometer unit is equipped with thefollowing:� a speedometer (which shows the riding

speed)� an odometer (which shows the total dis-

tance traveled)� two tripmeters (which show the distance

traveled since they were last set to zero)

� a clock� an hour meter (

the key has bee

Odometer and triPushing the “TRIPdisplay between tand the tripmeter mlowing order:ODO→TRIP A→TTo reset a tripmet“TRIP/ODO” buttoODO” button for atripmeters can betance that can be tel. This informatiofuture fuel stops.

NOTE:_

Holding in the “TRturning the key tobetween “mph” an_

EBU00843

cates the amount of fuel inisplay segments of the fuelwards “E” (Empty) as thes. When the “E” segment fuel level warning indica-uel cock to reserve and re-sible.

ator 2. Fuel gauge


4-6

Clock modePushing the “ ”/“ ” button for at least twoseconds switches the display between theclock mode “CLOCK” and the hour metermode “HOUR” in the following order. CLOCK→HOUR→CLOCK

To set the clock1. Push the “ ”/“ ” button until the clock

starts flashing.2. Set the hours by pushing the “H” button.3. Set the minutes by pushing the “M” but-

ton.4. Push the “ ”/“ ” button to set the

clock.

Fuel gauge The fuel gauge indithe fuel tank. The dgauge disappear tofuel level decreasedisappears and thetor flashes, set the ffuel as soon as pos

1. Fuel level warning indic3. “E” segment

eadlights with the engineore than thirty minutes. discharge to the pointmotor will not operateshould happen, removecharge it.

ch “ ”/“ ” engine stop switch is in the engine stop switch controlse used at all times to stopially in an emergency. Thert or run when the engined to “ ”.


4-7

EBU00053

Handlebar switches

1. Light switch “ / /OFF”2. Engine stop switch “ ”/“ ”3. Start switch “ ”

EBU01058

Light switch “ / /OFF” Set the switch to the “ ” position to turn onthe low beam and the tail/brake light. Set theswitch to the “ ” position to turn on the highbeam and the tail/brake light. Set the switch tothe “OFF” position to turn off all the lights.

CAUTION:_

Do not use the hturned off for mThe battery maythat the starter properly. If this the battery and re_

EBU00849

Engine stop switMake sure that the“ ” position. Theignition and can bthe engine, especengine will not stastop switch is turne

EBU00607

el drive switch “2WD”/“4WD”itch “LOCK”/“4WD”

r-wheel drive and differ-itches

ped with an on-commanditch “2WD”/“4WD” and a

ck switch “LOCK”/“4WD”.ate drive according to ter-ons. (2WD): Power is suppliedls only.


4-8

Start switch “ ”The starter motor cranks the engine when thisswitch is pushed.

CAUTION:See starting instructions prior to startingthe engine. (See page 6-1 for details.)

1. On-command four-whe2. Differential gear lock sw

EBU00842

On-command fouential gear lock swThis ATV is equipfour-wheel drive swdifferential gear loSelect the approprirain and the conditi� Two-wheel drive

to the rear whee

WARNING

ZARD 2WD to 4WD or fromOCK (“DIFF.LOCK”), or the ATV is moving. PEN

les differently in 2WD in 4WD-LOCK in someChanging from 2WD toWD to 4WD-LOCK, or moving may cause thetedly handle differently.act the operator and in-of losing control and an

THE HAZARD e ATV before changingD or from 4WD to 4WD-

ersa.


4-9

� Four-wheel drive (4WD): Power is suppliedto the rear and front wheels.

� Four-wheel drive with the differential gearlocked (4WD-LOCK): Power is supplied tothe rear and front wheels when the differen-tial gear is locked (“DIFF.LOCK”). Unlikethe 4WD mode, all wheels turn at the samespeed.

POTENTIAL HAChanging from4WD to 4WD-Lvice-versa whileWHAT CAN HAPThe ATV handthan in 4WD andcircumstances. 4WD or from 4vice-versa whileATV to unexpecThis could distrcrease the risk accident. HOW TO AVOIDAlways stop thfrom 2WD to 4WLOCK, or vice-v

itch “LOCK”/“4WD”

lock switch “LOCK”/

ial gear in 4WD, make sureur-wheel-drive switch is setTV, move the lever to po-set the switch to “LOCK”.l gear is locked, the differ-icator (“DIFF.LOCK”) light with the indicator “ ” init display. rential gear lock, stop theitch to “4WD”.

DIFF.LOCK


4-10

1. Lever2. On-command four-wheel drive switch “2WD”/“4WD”

On-command four-wheel drive switch“2WD”/“4WD” To change from 2WD to 4WD, stop the ATV,and then set the switch to “4WD”. When theATV is in 4WD, the 4WD indicator “ ” willcome on in the speedometer unit display. Tochange from 4WD to 2WD, stop the ATV, besure the lever is set to position a, and thenset the switch to “2WD”.

1. Differential gear lock sw2. Lever

Differential gear “4WD” To lock the differentthe on-command foto “4WD”, stop the Asition b, and then When the differentiaential gear lock indwill come on alongthe speedometer unTo release the diffeATV and set the sw

tch is set to “LOCK”, the dif-lock indicator light will flashential gear is locked. icator light is flashing, turn-bar back and forth will helpl gear lock to engage. the differential gear lock isged (e.g., when the indica-hing) will cause the engineimited until engagement is

V is in 4WD-LOCK, theveling speed is limited toph).


4-11

NOTE:_

� When the swiferential gear until the differ

� When the inding the handlethe differentia

� Riding beforeproperly engator light is flasspeed to be lcomplete.

� When the ATmaximum tra35 km/h (22 m

_

WARNING

POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed whenthe differential is locked, so it takesmore effort to turn the ATV. The amountof effort is more the faster you go. Youmay lose control and have an accident ifyou cannot make a sharp enough turnfor the speed you are traveling. HOW TO AVOID THE HAZARD Always ride at a slow speed when theATV is in 4WD-LOCK, and allow extratime and distance for maneuvers.

EBU00062

engine, check the throttleating smoothly. Make sure position as soon as the le-

WARNING

ARDrottle.PENld be hard to operate,lt to speed up or slow need to. This couldt.

THE HAZARDtion of the throttle leverhe engine. If it does notcheck for the cause.lem before riding theYamaha dealer if youe the problem yourself.


4-12

Throttle leverOnce the engine is running, movement of thethrottle lever will increase the engine speed.Regulate the speed of the machine by varyingthe throttle position. Because the throttle isspring-loaded, the machine will decelerate,and the engine will return to an idle any timethe hand is removed from the throttle lever.

1. Throttle lever

Before starting theto be sure it is operit returns to the idlever is released.

POTENTIAL HAZMalfunction of thWHAT CAN HAPThe throttle coumaking it difficudown when youcause an accidenHOW TO AVOID Check the operabefore you start twork smoothly, Correct the probATV. Consult a can’t find or solv

WARNING

ZARDment of the speed limit-

PENble could be damaged.e operation could result. control, have an acci-d.

THE HAZARDpeed adjuster out more

7 in). Always make surer free play is adjusted to.20 in). See page 8-36.


4-13

EBU00066

Speed limiterThe speed limiter keeps the throttle from fullyopening, even when the throttle lever ispushed to the maximum. Screwing in the ad-juster limits the maximum engine power avail-able and decreases the maximum speed ofthe ATV.

1. Locknut 2. Adjusting screwa. 12 mm (0.47 in)

POTENTIAL HAImproper adjuster and throttle.WHAT CAN HAPThe throttle caImproper throttlYou could losedent or be injureHOW TO AVOIDDo not turn the sthan 12 mm (0.4the throttle leve3–5 mm (0.12–0

EBU00070


4-14

Front brake leverThe front brake lever is located on the righthandlebar. Pull it toward the handlebar to ap-ply the front brake.

1. Front brake lever

EBU00073

Rear brake pedal and leverThe brake pedal is located on the right side ofthe machine and the brake lever is located onthe left handlebar. Push down on the pedal orpull the lever toward the handlebar to applythe rear brake.

1. Rear brake pedal

1. Rear brake lever


4-15

EBU00608

Drive select leverThe drive select lever is used to shift your ma-chine into the low, high, neutral, reverse andpark positions. (Refer to page 6-4 for the driveselect lever operation.)

1. Drive select lever

EBU00855

WARNING

ARD ine without setting ther to the park position

PEN tart to move unexpect- cause an accident.

THE HAZARD ct lever to the park po-ting the engine.


4-16

Recoil starterFirmly grasp the handle and pull slightly untilengagement can be felt. Then pull forcefully,being careful not to pull the rope all the wayout.

1. Recoil starter

POTENTIAL HAZStarting the engdrive select leve“P”. WHAT CAN HAPThe ATV could sedly, which couldHOW TO AVOID Set the drive selesition before star


4-17

EBU00092

Fuel tank capRemove the fuel tank cap by turning it coun-terclockwise.

1. Fuel tank cap

EBU00093


4-18

Fuel cockThe fuel cock supplies fuel from the fuel tankto the carburetor.The fuel cock has three positions.OFF: With the lever in this position fuel will

not flow. Always turn the lever to thisposition when the engine is not running.

ON: With the lever in this position, fuel flowsto the carburetor. Normal riding is donewith the lever in this position.

RES: This indicates reserve. If you run out offuel while riding, turn the lever to thisposition. THEN FILL THE FUEL TANKAT THE FIRST OPPORTUNITY. Afterrefuelling, return the fuel cock lever tothe “ON” position.

1. Arrow mark

1. Arrow mark

OFF Position

ON Position

”ine requires a richer air-fuele starter circuit supplies this

a to turn on the starter

b to turn off the starter

cold engine” for proper op- 6-1.)

”


4-19

1. Arrow mark

EBU00095

Starter (choke) “Starting a cold engmixture. A separatmixture.Move in direction(choke).Move in direction(choke).Refer to “Starting aeration. (See page

1. Starter (choke) “

RES Position

EBU00567

insert the projections ont into the seat holders andeat at the rear.

seat is securely fitted.


4-20

SeatTo remove the seat, pull the seat lock leverupward and pull up the seat at the rear.

1. Seat 2. Seat lock lever

To install the seat,the front of the seapush down on the s

NOTE:Make sure that the

mit: 45 kg (99 lb)

mit: 85 kg (187 lb)


4-21

EBU00858

Storage compartmentThe storage compartment is located underthe seat. (See page 4-20 for seat removal andinstallation procedures.)When storing the owner’s manual or otherdocuments in the storage compartment, besure to wrap them in a plastic bag so that theywill not get wet. When washing the ATV, becareful not to let any water enter the storagecompartment.

1. Storage compartment

EBU00582

Front carrier

EBU00583

Rear carrier

Maximum load li

Maximum load li

EBU01124

g ring

can be obtained at aake this adjustment.

: B ft) ard)


4-22

Front and rear shock absorber adjustment The spring preload can be adjusted to suit therider’s weight and riding conditions.

NOTE:_

When adjusting the rear shock absorbers, therear wheels need to be removed. (See page8-45 for removal and installation procedures.) _

Adjust the spring preload as follows. To increase the spring preload, turn the ad-justing ring in direction a. To decrease the spring preload, turn the ad-justing ring in direction b.

1. Spring preload adjustin

NOTE:_

A special wrenchYamaha dealer to m_

Standard positionA- Minimum (soE- Maximum (h

WARNING

ZARD absorber adjustment. PEN ent can cause poor

oss of stability, which accident. THE HAZARD he shock absorbers ont side to the same set-


4-23

1. Special wrench

POTENTIAL HAImproper shockWHAT CAN HAPUneven adjustmhandling and lcould lead to anHOW TO AVOIDAlways adjust tthe left and righting.

EBU01002

apacity for the auxiliary

(10 A)


4-24

Auxiliary DC jackThe auxiliary DC jack is located at the frontright side of the ATV. The auxiliary DC jack can be used for suitablework lights, radios, etc. The auxiliary DC jack should only be usedwhen the engine is running.

1. Auxiliary DC jack cap

1. Set the light switch to “OFF”.2. Start the engine. (See pages 6-1–6-3.)3. Open the auxiliary DC jack cap, and then

insert the accessory power plug into thejack.

1. Auxiliary DC jack

Maximum rated cDC jack:

DC 12 V, 120 W

ntial hazard that couldinjury or death.


4-25

4. When the auxiliary DC jack is not beingused, cover it with the cap.

CAUTION:_

� Do not use accessories requiringmore than the above maximum capac-ity. This may overload the circuit andcause the fuse to blow.

� If accessories are used without theengine running or with the headlightsturned on, the battery will lose itscharge and engine starting may be-come difficult.

� Do not use an automotive cigarettelighter or other accessories with aplug that gets hot because the jackcan be damaged.

_

EBU00112

WARNINGIndicates a poteresult in serious


1

2

3

4

5

6

7

8

9

10

11

12

13

14

PAGE

ge. 5-2–5-3,8-36–8-42

5-4–5-5

5-6, 8-12–8-16

8-20–8-24

5-7, 8-16–8-19

5-9, 8-36

5-10–5-13,8-45–8-46

5-9

5-9, 8-51–8-53

8-25


5-1

PRE-OPERATION CHECKS

Before using this machine, check the following points:

ITEM ROUTINE

Brakes • Check operation, free play, fluid level and fluid leaka• Fill with DOT 4 brake fluid if necessary.

Fuel • Check fuel level. • Fill with fuel if necessary.

Engine oil • Check oil level. • Fill with oil if necessary.

Coolant reservoir tank • Check coolant level.• Fill with coolant if necessary.

Final gear oil/Differential gear oil • Check for leakage.

Throttle • Check for proper throttle cable operation.

Wheels and tires • Check tire pressure, wear and damage.

Fittings and Fasteners • Check all fittings and fasteners.

Lights • Check for proper operation.

Axle boots • Check for damage.

EBU00854

kesrake pedal

ee play in the brake levers the free play is incorrect,s 8-39–8-42.) n of the brake levers andhould move smoothly andm feeling when the brakeshave the machine inspect-aler.

id level. sary. (See pages 8-37–

rake fluid: DOT 4


5-2

Front and rear braBrake levers and bCheck for correct frand brake pedal. Ifadjust it. (See pageCheck the operatiobrake pedal. They sthere should be a firare applied. If not, ed by a Yamaha de

Brake fluid levelCheck the brake fluAdd fluid if neces8-39.)

WARNING

POTENTIAL HAZARDFailure to inspect the ATV before oper-ating. Failure to properly maintain the ATV.WHAT CAN HAPPENIncreases the possibility of an accidentor equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV each time youuse it to make sure the ATV is in safe op-erating condition.Always follow the inspection and main-tenance procedures and schedules de-scribed in the Owner’s Manual.

Recommended b

WARNING

ZARD improperly operating

PEN braking ability, which accident. THE HAZARD e brakes at the start of

not ride the ATV if youm with the brakes. If a be corrected by the ad-dures provided in thishe ATV inspected by a


5-3

Brake fluid leakageCheck to see if any brake fluid is leaking out ofthe pipe joints or master cylinder. Apply thebrakes firmly for one minute. If there is anyleaking, have the machine inspected by aYamaha dealer.

Brake operationTest the brakes at slow speed after startingout to make sure they are working properly. Ifthe brakes do not provide proper braking per-formance, inspect the brake pads for wear.(See pages 8-36–8-37.)

POTENTIAL HARiding with brakes. WHAT CAN HAPYou could losecould lead to anHOW TO AVOIDAlways check thevery ride. Do find any probleproblem cannotjustment procemanual, have tYamaha dealer.

EBU01085

ine has been designed toed gasoline with a pump+M]/2) of 86 or higher, orumber of 91 or higher. Ifg occurs, use a differentr premium unleaded fuel.ive you longer spark plugintenance cost.

s of gasohol; gasohol con- that containing methanol. ethanol can be used ifs not exceed 10%. Gaso-anol is not recommendede it may cause fuel systemperformance problems.


5-4

FuelMake sure there is sufficient gasoline in thetank.

CAUTION:_

Use only unleaded gasoline. The use ofleaded gasoline will cause severe damageto internal engine parts, such as the valvesand piston rings, as well as to the exhaustsystem. _

Your Yamaha enguse regular unleadoctane number ([Rresearch octane nknocking or pinginbrand of gasoline oUnleaded fuel will glife and reduced ma

Gasohol There are two typetaining ethanol andGasohol containingethanol content doehol containing methby Yamaha becausdamage or vehicle

Recommended fuel: UNLEADED GASOLINE ONLY

Fuel tank capacity: Total:

20 L (4.40 Imp gal, 5.28 US gal) Reserve:

3.5 L (0.77 Imp gal, 0.92 US gal)

WARNING

ZARD hen refueling. PEN

which can cause a firey. hen it heats up. If the

filled, fuel could spill out the engine or the sun. THE HAZARD he fuel tank. Be carefulespecially on the engine Wipe up any spilled fuel sure the fuel tank cap is. ht after the engine hasd is still very hot.


5-5

1. Fuel level 2. Filler tube

POTENTIAL HAImproper care wWHAT CAN HAPFuel can spill, and severe injurFuel expands wfuel tank is overdue to heat fromHOW TO AVOIDDo not overfill tnot to spill fuel, or exhaust pipe.immediately. Beclosed securelyDo not refuel rigbeen running an

EBU01084

revent clutch slippagegine oil also lubricateso not mix any chemicalnot use oils with a dieselof “CD” or oils of a high-n specified. In addition,oils labeled “ENERGY II” or higher. t no foreign material en-case.

nge: p qt, 2.01 US qt)

placement: p qt, 2.11 US qt)

p qt, 2.33 US qt)


5-6

Engine oilMake sure the engine oil is at the specifiedlevel. Add oil as necessary. (See page 8-12.)

CAUTION:_

� In order to p(since the enthe clutch), dadditives. Do specification er quality thado not use CONSERVING

� Make sure thaters the crank

_

0° 10° 30° 50° 70° 90° 110°

YAMALUBE 4 (10W30) or SAE 10W30

-20° -10° 0° 10° 20° 30° 40°

YAMALUBE 4 (20W40) or SAE 20W40

SAE 5W30

130°F

50°C

Recommended oil:

Recommended engine oil classification:API Service SE, SF, SG type or higher Oil quantity:

Periodic oil cha1.9 L (1.67 Im

With oil filter re2.0 L (1.76 Im

Total amount: 2.2 L (19.4 Im

ilfferential gear oil is at thed oil as necessary. (See

or details.)

level in the coolant reser-ne is cold. (The coolant lev-engine temperature.) Theisfactory if it is between theevel marks on the coolantlant level is at or below thedd tap water (soft water) to

o upper level mark. Change two years. (See pagesils.)

oil:L-4 Hypoid gear oil


5-7

EBU00493

Final gear oilMake sure the final gear oil is at the specifiedlevel. Add oil as necessary. (See pages 8-16–8-17 for details.)

If desired, an SAE 80W90 hypoid gear oil maybe used for all conditions.

NOTE:GL-4 is a quality and additive rating, GL-5 orGL-6 rated hypoid gear oils may also be used.

EBU00678

Differential gear oMake sure the dispecified level. Adpages 8-18–8-19 f

EBU01127

Coolant Check the coolantvoir when the engiel will vary with coolant level is satupper and lower lreservoir. If the coolower level mark, abring the level up tthe coolant every8-21–8-24 for deta

Recommended oil:SAE 80 API GL-4 Hypoid gear oil

Recommended SAE 80 API G

WARNING

ARD diator cap when the en- are still hot. PEN rned by hot fluid and

under pressure. THE HAZARD ine to cool before re-tor cap. Always use a

he cap. Allow any re-re to escape beforeving the cap.


5-8

CAUTION:_

Hard water or salt water is harmful to theengine. You may use distilled water if youcannot get soft water. _

Coolant reservoir capacity: 0.3 L (0.26 Imp qt, 0.32 US qt)

POTENTIAL HAZRemoving the ragine and radiatorWHAT CAN HAPYou could be busteam blown outHOW TO AVOID Wait for the engmoving the radiathick rag over tmaining pressucompletely remo

n of all switches. Repair aser operation.


5-9

EBU01083

Throttle leverCheck to see that the throttle lever operatescorrectly. It must open smoothly and springback to the idle position when released. Havea Yamaha dealer repair as necessary forproper operation.

EBU00152

Fittings and FastenersAlways check the tightness of chassis fittingsand fasteners before a ride. Take the machineto a Yamaha dealer or refer to the ServiceManual for correct tightening torque.

EBU00991

LightsCheck the headlights and tail/brake light tomake sure they are in working condition. Re-pair as necessary for proper operation.

EBU01082

SwitchesCheck the operationecessary for prop

EBU00157

ould be set to the rec-ressure: tire pressure

0.35 kgf/cm2, 5.0 psi)0.30 kgf/cm2, 4.3 psi)ust tire pressures whenld. must be equal on both

e below the minimumuld cause the tire to

m the rim under severetions. g are minimums:0.32 kgf/cm2, 4.6 psi)0.27 kgf/cm2, 3.9 psi)


5-10

Tires

WARNING

POTENTIAL HAZARDOperating this ATV with improper tires,or with improper or uneven tire pres-sure.WHAT CAN HAPPENUse of improper tires on this ATV, or op-eration of this ATV with improper or un-even tire pressure, may cause loss ofcontrol, increasing your risk of accident.HOW TO AVOID THE HAZARD1. The tires listed below have been ap-

proved by Yamaha Motor Co., Ltd.for this model. Other tire combina-tions are not recommended.

ACE-01EACE-01E

Manufacturer Size Type

Front DUNLOP AT25 × 8-12 KT131

Rear DUNLOP AT25 × 10-12 KT135

2. The tires shommended p

� RecommendedFront 35 kPa (Rear 30 kPa (

� Check and adjthe tires are co

� Tire pressuressides.

3. Tire pressurspecified codislodge froriding condiThe followin

Front 32 kPa (Rear 27 kPa (


5-11

4. Use no more than the followingpressures when seating the tirebeads.

Front 250 kPa (2.5 kgf/cm2, 36 psi)Rear 250 kPa (2.5 kgf/cm2, 36 psi)

Higher pressures may cause thetire to burst. Inflate the tires veryslowly and carefully. Fast inflationcould cause the tire to burst.

EBU00159

e


5-12

How to measure tire pressureUse the low-pressure tire gauge.

NOTE:The low-pressure tire gauge is included asstandard equipment. Make two measure-ments of the tire pressure and use the secondreading. Dust or dirt in the gauge could causethe first reading to be incorrect.

Set pressure with tires cold.Set tire pressures to the following specifica-tions:ACE-02EACE-02E

1. Low-pressure tire gaug

Recommended pressure

Minimum Maximum

Front35 kPa

(0.35 kgf/cm2, 5.0 psi)

32 kPa (0.32 kgf/cm2,

4.6 psi)

38 kPa (0.38 kgf/cm2,

5.4 psi)

Rear30 kPa

(0.30 kgf/cm2, 4.3 psi)

27 kPa (0.27 kgf/cm2,

3.9 psi)

33 kPa (0.33 kgf/cm2,

4.7 psi)


5-13

EBU00160

Tire wear limitWhen the tire groove decreases to 3 mm(0.12 in) due to wear, replace the tire.

a. 3 mm (0.12 in)

EBU00161 EBU00672

gine

brake lever.ock to “ON”.switch to “ON” and the en-h to “ ”.elect lever into the neutral.

WARNING

ARD cables in cold weather.PENable to control the ATV, to an accident or colli-

THE HAZARDcold weather, alwayscontrol cables work

you begin riding.


6-1

OPERATION


Starting a cold en

1. Apply the rear 2. Turn the fuel c3. Turn the main

gine stop switc4. Shift the drive s

or park position

WARNING

POTENTIAL HAZARDOperating ATV without being familiarwith all controls.WHAT CAN HAPPENLoss of control, which could cause anaccident or injury.HOW TO AVOID THE HAZARDRead the Owner’s Manual carefully. Ifthere is a control or function you do notunderstand, ask your Yamaha dealer.

POTENTIAL HAZFreezing controlWHAT CAN HAPYou could be unwhich could leadsion.HOW TO AVOID When riding in make sure all smoothly before

1

2

3

4

5

6

7

8

9

10

11

12

13

14

engine start-ent temperature above (80 °F) and warm engine

position.

1. Fully open3. Closed

lose the throttle lever andine by pushing the start


6-2

NOTE:� When the drive select lever is in the neu-

tral or park position, if either indicator lightdoes not come on, ask a Yamaha dealerto inspect its electric circuit.

� The engine can be started in any gear ifthe rear brake lever is applied. However,it is recommended to shift into neutral orpark before starting the engine.

5. Use the starter (choke) in reference tothe figure:

Position 1 : Cold engine start-ambient temperature below 5 °C(40 °F).

Position 2 : Cold engine start-ambient temperature at 0 °C(30 °F)–30 °C (90 °F) and warm-ing up position.

Position 3 : Cold ambi25 °Cstart

a. Starter (choke)2. Half open

6. Completely cstart the engswitch.

reak-in” section prior toine for the first time.

ngineine, refer to the “Starting aion. The starter (choke)d. The throttle should be

ngine life, always warm uptarting off. Never acceler- engine! To see whether orrm, check if it responds to

ly with the starter (choke)


6-3

NOTE:� If the engine fails to start, release the

start switch, then push the start switchagain. Pause a few seconds before thenext attempt. Each cranking should be asshort as possible to preserve battery en-ergy. Do not crank the engine more than10 seconds on each attempt.

� If the battery is discharged, pull the recoilstarter to start the engine.

7. If the engine is started with the starter(choke) in position 1, the starter (choke)should be returned to position 2 to warmup the engine. If the engine is started withthe starter (choke) in position 2, keepthe starter (choke) in this position towarm up the engine.

8. Continue warming up the engine until itidles smoothly and return the starter(choke) to position 3 before riding.

CAUTION:See the “Engine boperating the eng

EBU00180

Starting a warm eTo start a warm engcold engine” sectshould not be useopened slightly.

EBU00182

Warming upTo get maximum ethe engine before sate hard with a coldnot the engine is wathe throttle normalturned off.

ttle lever gradually.


6-4

EBU00846

Drive select lever operation and reverse driving

CAUTION:_

Before shifting, you must stop the ma-chine and return the throttle lever to theclosed position. Otherwise, the transmis-sion may be damaged. _

Shifting: Neutral to High and High to Low1. Bring the machine to a complete stop

and return the throttle lever to the closedposition.

2. Apply the brakes, then shift by movingthe drive select lever along the shiftguide.

NOTE:_

Make sure that the drive select lever is com-pletely shifted into position. _


3. Open the thro

rse, the reverse indicator on. If the light does not Yamaha dealer to inspectdicator light electrical cir-

chronizing mechanism in light may not come on un-ts moving.

for people or obstacles,e rear brake pedal.


6-5

Shifting: Neutral to Reverse and Reverseto Park

NOTE:_

The drive select lever cannot be shifted into orfrom reverse or park without applying the rearbrake. _

1. Bring the machine to a complete stopand return the throttle lever to the closedposition.

2. Apply the rear brake pedal.3. Shift from neutral to reverse or from re-

verse to park and vice versa by movingthe drive select lever along the shiftguide.


NOTE:_

� When in revelight should become on, ask athe reverse incuit.

� Due to the synthe engine, thetil the ATV star

_

4. Check behindthen release th


6-6

5. Open the throttle lever gradually and con-tinue to watch to the rear while backing.

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person be-hind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make surethere are no obstacles or people behindyou. When it is safe to proceed, go slow-ly.

EBU00210

acceleration sequence with a substantial rest pe-by cruising at lower r/minrid itself of the temporaryany abnormality is noticedonsult a Yamaha dealer.

ous operation above halfa cooling off period of five after every hour of opera-peed of the machine fromo not operate it at one set.


6-7

Engine break-inThere is never a more important period in thelife of your machine than the period betweenzero and 20 hours. For this reason, we ask that you carefully readthe following material. Because the engine isbrand new, you must not put an excessiveload on it for the first several hours of running.During the first 20 hours, the various parts inthe engine wear and polish themselves to thecorrect operating clearances. During this period, prolonged full throttle oper-ation or any condition which might result in ex-cessive engine heating must be avoided.However, momentary (2–3 seconds maxi-mum) full throttle operation under load doesnot harm the engine.

Each full throttleshould be followedriod for the engine so the engine can build up of heat. If during this period, c1. 0–10 hours:

Avoid continuthrottle. Allow to ten minutestion. Vary the stime to time. Dthrottle position

p the engine and shift theinto the park position, theno the “OFF” position.


6-8

2. 10–20 hours: Avoid prolonged operation above 3/4throttle. Rev the machine freely but donot use full throttle at any time.

3. After break-in: Avoid prolonged full throttle operation.Vary speeds occasionally.

EBU00612

ParkingWhen parking, stodrive select lever turn the fuel cock t

EBU00615

hine to a stop by applying

e. brake applied, shift theer to the park position.


6-9

Parking on a slope 1. Bring the macthe brakes.

2. Stop the engin3. With the rear

drive select lev

WARNING

POTENTIAL HAZARDParking on a hill or other incline.WHAT CAN HAPPENThe ATV could roll out of control, in-creasing the chance of an accident.HOW TO AVOID THE HAZARDAvoid parking on hills or other inclines.If you must park on an incline, place themachine transversely across the in-cline, apply the parking brake, and blockthe front and rear wheels with rocks orother objects.Do not park the ATV at all on hills thatare so steep you could not walk up themeasily.

uld be rigidly and securelycessory which can shift po-ff while you are riding couldy to control the ATV.n accessory where it couldur ability to control the ATV.e (but are not limited to) a

object attached to the han-ould make steering difficult,at limits your ability to moveeat, or one that limits your

n when riding an ATV withe ATV may handle differ-s without accessories.


6-10

EBU00221

Accessories and loading

EBU00222

AccessoriesAccessories can affect the handling and con-trol of your ATV. Keep the following in mindwhen considering an accessory or operatingan ATV which has accessories.� Choose only accessories designed for your

ATV. Your Yamaha dealer has a variety ofgenuine Yamaha accessories. Other ac-cessories may also be available on themarket. However, it is not possible forYamaha to test all non-Yamaha accesso-ries, nor have any control over the quality orsuitability of them. Choose a genuineYamaha accessory, or one that is equiva-lent in design and quality.

� Accessories shomounted. An acsition or come oaffect your abilit

� Do not mount ainterfere with yoExamples includheavy or bulky dlebars which can accessory tharound on the sview.

� Use extra cautioaccessories. Thently than it doe

EBU00960

the maximum tongue measure tongue weight scale. Put the tongue ofr on the scale with the

eight. Adjust the load in thery, to reduce the weight onarrying cargo and towing ahe tongue weight in the load limit.

he carrier as close to theicle as possible. Put cargoe rear carrier. Center the side. securely to the carriers. in the trailer cannot moveg load can cause an acci-

ad does not interfere withbility to see where you are


6-11

Loading Cargo or a trailer can change the stability andhandling of an ATV. You must use common sense and good judg-ment when carrying cargo or towing a trailer.Keep the following points in mind: � Never exceed the weight limits shown. An

overloaded ATV can be unstable.

� Do not exceedweight. You canwith a bathroomthe loaded trailetongue at hitch htrailer, if necessahitch. If you are ctrailer, include tmaximum vehicle

� Load cargo on tcenter of the vehat the front of thload from side to

� Tie down cargoMake sure cargoaround. A shiftindent.

� Make sure the locontrols or your agoing.

MAXIMUM LOADING LIMIT � Vehicle loading limit (total weight of

cargo, rider and accessories, and tongue weight): 220 kg (485 lb)

� Front carrier: 45 kg (99 lb) � Rear carrier: 85 kg (187 lb) � Storage box: 2.0 kg (4.4 lb) � Trailer hitch:

Pulling load (total weight of trailer and cargo): 550 kgf (1,212 lbf) Tongue weight (vertical weight on trailer hitch point): 15 kgf (33 lbf)

WARNING

ZARD ATV or carrying or tow-perly. PEN anges in vehicle han-

ld lead to an accident. THE HAZARD he stated load capacity

be properly distributedached. when carrying cargo or. Allow greater distance


6-12

� Ride more slowly than you would without aload. The more weight you carry, the slow-er you should go. Although conditions vary,it is good practice not to exceed low rangewhenever you are carrying heavier loads orwhen towing a trailer.

� Allow more braking distance. A heavier ve-hicle takes longer to stop.

� Avoid making sharp turns unless at veryslow speeds.

� Avoid hills and rough terrain. Choose ter-rain carefully. Added weight affects the sta-bility and handling of the ATV.

POTENTIAL HAOverloading thising cargo improWHAT CAN HAPCould cause chdling which couHOW TO AVOIDNever exceed tfor this ATV. Cargo should and securely attReduce speed pulling a trailerfor braking.

d


6-13

EBU00956

WARNING_

Indicates a potential hazard that coulresult in serious injury or death.

7


Riding

Your

ATV

7-1


7-2

WAR_

Indicates result in s

GETTINGThis ATV ibe used fyour ATVstructions and technhowever, riding. Ridacquired ttime. Takeniques wemaneuvers.

have read this Owner’s Man-d understand the operation ofy particular attention to then on pages 2-1–2-6. Pleaseution and warning labels on


7-3

Riding your new ATV can be a very enjoyableactivity, providing you with hours of pleasure.But it is essential to familiarize yourself with theoperation of the ATV to achieve the skill neces-sary to enjoy riding safely. Before you begin to

NINGa potential hazard that could

erious injury or death.

TO KNOW YOUR ATV s mainly for utility use, but may alsoor recreation. This section, Riding, provides general ATV riding in-for recreational riding. The skillsiques described in this section,are appropriate for all types ofing your ATV requires special skillshrough practice over a period of the time to learn the basic tech-ll before attempting more difficult

ride, be sure youual completely anthe controls. Pasafety informatioalso read all cayour ATV.

hine requires skills ac-ractice over a period of

arn the basic techniquesting more difficult maneu-

THE HAZARD experienced operators the certified training

y Yamaha. They shouldactice the skills learnedd the operating tech- in this Owner’s Manu-

nformation about thecontact an authorized

ll 1-800-887-2887.


7-4

RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced. Beginners should get training from a certifiedinstructor. Become familiar with this ATV at slow speedsfirst, even if you are an experienced operator.Do not attempt to operate at maximum perfor-mance until you are totally familiar with themachine’s handling and performance charac-teristics.

Riding your macquired through ptime. Take the time to lewell before attempvers.

WARNING

POTENTIAL HAZARD Operating this ATV without proper in-struction. WHAT CAN HAPPEN The risk of an accident is greatly in-creased if the operator does not knowhow to operate the ATV properly in dif-ferent situations and on different typesof terrain.

HOW TO AVOID Beginning and inshould completecourse offered bthen regularly prin the course anniques describedal. For more itraining course, ATV dealer or ca


7-5

Not recommended for children under16 years of age.

WARNING

POTENTIAL HAZARD Failure to follow the age recommenda-tions for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec-ommended for their age can lead to se-vere injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operatean ATV with engine size greater than90cc.


7-6

This machine is designed to carry operatorand cargo only - passengers prohibited.

WARNING

POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balanceand control this ATV. Could cause anaccident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seatis to allow the operator to shift positionas needed during operation. It is not forcarrying passengers.

out protective clothinghances of severe injuryn accident. THE HAZARD n approved motorcycle

roperly. wear:n face shield)

shirt or jacket


7-7

Apparel

WARNINGApparel POTENTIAL HAZARD Operating this ATV without wearing anapproved motorcycle helmet, eye pro-tection and protective clothing. WHAT CAN HAPPEN Operating without anapproved motor-cycle helmet increas-es your chances of asevere head injury ordeath in the event ofan accident.Operating withouteye protection canresult in an accident and increases yourchances of a severe injury in the eventof an accident.

Operating withincreases your cin the event of aHOW TO AVOIDAlways wear ahelmet that fits pYou should also

eye protectio(goggles or

glovesbootslong-sleevedlong pants

WARNING

ARD TV after consuming al-

PEN affect your judgment. to react more slowly. r balance and percep-

n accident. THE HAZARD alcohol or drugs beforehis ATV.


7-8

Do not operate after consuming alcohol ordrugs. Operator’s performance capability is reducedby the influence of alcohol or drugs.

POTENTIAL HAZOperating this Acohol or drugs. WHAT CAN HAPCould seriously Could cause youCould affect yoution.Could result in aHOW TO AVOID Never consume or while driving t

WARNING

ZARD TV with improper tires,

er or uneven tire pres-

PEN tires on this ATV, or op-TV with improper or un-ure, may cause loss ofing your risk of an acci-

THE HAZARD size and type tires spec-r’s Manual for this vehi-lways maintain proper described in the Own-age 5-10.


7-9

Pre-operation checks Always perform the pre-operation checks list-ed on page 5-1 before riding for safety andproper care of the machine.

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before oper-ating.Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accidentor equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time youuse it to make sure the ATV is in safe op-erating condition. Always follow the in-spection and maintenance proceduresand schedules described in the Owner’sManual.

POTENTIAL HAOperating this Aor with impropsure. WHAT CAN HAPUse of impropereration of this Aeven tire presscontrol, increasdent. HOW TO AVOIDAlways use the ified in the Ownecle on pages. Atire pressure aser’s Manual on p

erienced with this model,ped with a speed limiter inousing. The speed limiterfrom fully opening, evenver is pushed to the maxi-he adjuster limits the max-r available and decreasesd of the ATV. Turning the top speed and turning it

peed.

2. Adjusting bolt


7-10

WARNING_

Indicates a potential hazard that couldresult in serious injury or death.

Do not operate at speeds too fast for yourskills or the conditions.

Speed limiter For riders less expthis model is equipthe throttle lever hkeeps the throttle when the throttle lemum. Screwing in timum engine powethe maximum speescrew in decreasesout increases top s

1. Locknut

WARNING

POTENTIAL HAZARD Operating this ATV at speeds too fastfor your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing con-trol of the ATV, which can result in anaccident. HOW TO AVOID THE HAZARD Always go at a speed that is proper forthe terrain, visibility and operating con-ditions, and your experience.

WARNING

ZARD ATV or carrying or tow-perly. PEN anges in vehicle han-

ld lead to an accident. THE HAZARD he stated load capacity

be properly distributedached. when carrying cargo or. Allow greater distance

he instructions in yourl for carrying cargo or


7-11

Loading and accessories Use extra caution when riding the machinewith additional loads, such as accessories orcargo. The machine’s handling may be ad-versely affected. Reduce your speed whenadding additional loads.

MAXIMUM LOADING LIMIT � Vehicle loading limit: 220 kg (485 lb)

* Total weight of cargo, rider and accessories, and trailer hitch vertical load.

� Front carrier: 45 kg (99 lb) � Rear carrier: 85 kg (187 lb) � Storage box: 2.0 kg (4.4 lb) � Trailer hitch:

Pulling load: 550 kgf (1,212 lbf) Total weight of trailer and cargo. Tongue weight: 15 kgf (33 lbf) Vertical weight on trailer hitch point.

POTENTIAL HAOverloading thising cargo improWHAT CAN HAPCould cause chdling which couHOW TO AVOIDNever exceed tfor this ATV. Cargo should and securely attReduce speed pulling a trailerfor braking. Always follow tOwner’s Manuapulling a trailer.

WARNING

ARD s from handlebars orrds during operation.

PEN ne hand or foot can re- to control the ATV or to lose your balance

e ATV. If you remove aboard, your foot or legcontact with the rearuld injure you or cause

THE HAZARD h hands on the handle-et on the footboards of operation.


7-12

During operation Always keep your feet on the footboards dur-ing operation. Otherwise your feet may con-tact the rear wheels.

POTENTIAL HAZRemoving handfeet from footboaWHAT CAN HAPRemoving even oduce your abilitycould cause youand fall off of thfoot from a footmay come into wheels, which coan accident. HOW TO AVOID Always keep botbars and both feyour ATV during


7-13

Avoid wheelies and jumping. You may losecontrol of the machine or overturn.

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps, and otherstunts. WHAT CAN HAPPEN Increases the chance of an accident, in-cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheeliesor jumps. Don’t try to show off.


7-14

Modifications

WARNING

POTENTIAL HAZARD Operating this ATV with improper modi-fications. WHAT CAN HAPPEN Improper installation of accessories ormodification of this vehicle may causechanges in handling which in some situ-ations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improp-er installation or use of accessories. Allparts and accessories added to this ve-hicle should be genuine Yamaha orequivalent components designed foruse on this ATV and should be installedand used according to instructions. Ifyou have questions, consult an autho-rized ATV dealer.

e hot exhaust system.e machine in a placeght be likely to touch it.


7-15

Exhaust system The exhaust system on the machine is veryhot during and following operation. To preventburns, avoid touching the exhaust system.Park the machine in a place where pedestri-ans or children are not likely to touch it.

WARNING

POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustiblematerial accumulated around the en-gine area could catch fire.Someone touching the exhaust systemduring or after operation could beburned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV indry grass or other dry ground cover.Keep the engine area free of dry grass,brush, or other combustible material.

Do not touch thDo not park thwhere others mi


7-16

BE CAREFUL WHERE YOU RIDE This machine is designed for off-road useonly. Riding on paved surfaces can causeloss of control.

WARNING

POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only.Paved surfaces may seriously affecthandling and control of the ATV, andmay cause the vehicle to go out of con-trol. HOW TO AVOID THE HAZARD Always avoid paved surfaces, includingsidewalks, driveways, parking lots andstreets.


7-17

Do not ride on any public road, street, or high-way.Riding on public roads can result in collisionswith other vehicles.

WARNING

POTENTIAL HAZARD Operating this ATV on public streets,roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any publicstreet, road or highway, even a dirt orgravel one. In many states it is illegal tooperate ATVs on public streets, roadsand highways.


7-18

Know the terrain where you ride. Ride cau-tiously in unfamiliar areas. Stay alert forholes, rocks, or roots in the terrain, and oth-er hidden hazards which may cause the ma-chine to upset.

WARNING

POTENTIAL HAZARD Failure to use extra care when operatingthis ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks,bumps, or holes, without enough time toreact. Could result in the ATV overturn-ing or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when op-erating on unfamiliar terrain. Always bealert to changing terrain conditionswhen operating the ATV.


7-19

WARNING

POTENTIAL HAZARD Failure to use extra care when operatingon excessively rough, slippery or looseterrain. WHAT CAN HAPPEN Could cause loss of traction or vehiclecontrol, which could result in an acci-dent, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough,slippery or loose terrain until you havelearned and practiced the skills neces-sary to control the ATV on such terrain.Always be especially cautious on thesekinds of terrain.

s posted “no trespassing”.te property without getting

PEN a collision. You could

THE HAZARD caution flag on the ma-ou more visible. Watchr vehicles.


7-20

When riding in an area where you might noteasily be seen, such as desert terrain, mounta caution flag on the machine. DO NOT usethe flag pole bracket as a trailer hitch.

Do not ride in areaDo not ride on privapermission.

WARNING

POTENTIAL HAZARD Operating in areas where you might notbe seen by other off-road vehicles.

WHAT CAN HAPYou could be inbe injured. HOW TO AVOID Always mount a chine to make ycarefully for othe

ing, shift the drive select le-tion “L” or the high positionottle slowly and smoothly.tch will engage and you will If the throttle is applied toot wheels may lift off the a loss of directional con-speeds until you are thor- the operation of your ATV.

n or stopping, release the the brakes smoothly andse of the brakes can causection, reducing control andsibility of an accident.

drive position low “L” toersa without coming to aamage to the engine or

ccur.


7-21

Select a large, flat area off-road to become fa-miliar with your ATV. Make sure that this areais free of obstacles and other riders. Youshould practice control of the throttle, brakes,shifting procedures, and turning techniques inthis area before trying more difficult terrain. Al-ways avoid riding on paved surfaces: the ATVis designed for off-road use only, and han-dling maneuvers are more difficult to performon pavement.

Shift to the parking position “P” and follow theinstruction on page 6-1 to start the engine.Once it has warmed up you are ready to beginriding your ATV. Remember that the engineand exhaust pipe will be hot when riding andafterwards; do not allow skin or clothing tocome in contact with these components.

With the engine idlver to the low posi“H”. Apply the thrThe centrifugal clustart to accelerate.abruptly, the fronground resulting introl. Avoid higher oughly familiar with

When slowing dowthrottle and applyevenly. Improper uthe tires to lose traincreasing the pos

CAUTION:_

Do not shift fromhigh “H” or vice vcomplete stop. Ddrive train may o_

curve, slow down and be-lebars in the desired direc-, put your weight on thetside of the turn (oppositeion) and lean your upperse the throttle to maintain

ugh the turn. This maneu-el on the inside of the turng the ATV to make the turn

THE HAZARD roper procedures forribed in this Owner’s turning at low speedsng to turn at fasterturn at speeds too fastthe conditions. Operatend allow extra time andeuvers when in 4WD-CK”).


7-22

TURNING YOUR ATV To achieve maximum traction while riding off-road in 2WD or 4WD, the two rear wheels aremounted solidly on one axle and turn togetherat the same speed. Furthermore, when riding in4WD-LOCK (“DIFF. LOCK”), the front wheelsalso turn together at the same speed. There-fore, unless the wheel on the inside of the turnis allowed to slip or lose some traction, the ATVwill resist turning. A special turning techniquemust be used to allow the ATV to make turnsquickly and easily. It is essential that this skill belearned first at low speed.

As you approach agin to turn the handtion. As you do sofootboard to the ouyour desired directbody into the turn. Uan even speed throver will let the wheslip slightly, allowinproperly.

WARNING

POTENTIAL HAZARD Turning improperly.WHAT CAN HAPPEN ATV could go out of control, causing acollision or overturn.

HOW TO AVOID Always follow pturning as descManual. Practicebefore attemptispeeds. Do not for your skills or at a slow speed adistance for manLOCK (“DIFF. LO

arned this technique youperform it at higher speeds.

rocedures such as abruptxcessive braking, incorrect

or too much speed for theurn may cause the ATV toins to tip over to the outside turn, lean more to the in-

e necessary to gradually letand steer to the outside ofping over.

higher speeds until you are with the operation of your


7-23

This procedure should be practiced at slowspeed many times in a large off-road areawith no obstacles. If an incorrect technique isused, your ATV may continue to go straight. Ifthe ATV doesn’t turn, come to a stop and thenpractice the procedure again. If the riding sur-face is slippery or loose, it may help to posi-tion more of your weight over the front wheelsby moving forward on the seat.

Once you have leshould be able to or in tighter curves

Improper riding pthrottle changes, ebody movements,sharpness of the ttip. If the ATV begwhile negotiating aside. It may also boff on the throttle the turn to avoid tipRemember: Avoidthoroughly familiarATV.

n climbing a hill to makeht is transferred forward onbe accomplished by lean- steeper inclines, standingand leaning forward over

THE HAZARD e ATV on hills too steepr your abilities. Practiceefore attempting large


7-24

CLIMBING UPHILL Use proper riding techniques to avoid vehicleoverturns on hills. Be sure that you can ma-neuver your ATV well on flat ground before at-tempting any incline and then practice ridingfirst on gentle slopes. Try more difficult climbsonly after you have developed your skill. In allcases avoid inclines with slippery or loose sur-faces, or obstacles that might cause you tolose control.

It is important whesure that your weigthe ATV. This can ing forward and, onon the footboards the handlebars.

WARNING

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily onextremely steep hills than on level sur-faces or small hills.

HOW TO AVOID Never operate thfor the ATV or foon smaller hills bhills.

sharp drop, or anothern could be on the other


7-25

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause theATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures forclimbing hills as described in this Own-er’s Manual.Always check the terrain carefully be-fore you start up any hill.Never climb hills with excessively slip-pery or loose surfaces.Shift your weight forward.Never open the throttle suddenly.The ATV could flip over backwards. Never go over the top of any hill at highspeed.

An obstacle, a vehicle or persoside of the hill.

WARNING

ARD ing hills or turning on

PEN of control or cause the

THE HAZARD turn the ATV around

you have mastered thee as described in the on level ground. Ben turning on any hill.

he side of a steep hill if


7-26

If you are climbing a hill and you find that youhave not properly judged your ability to makeit to the top, you should turn the ATV aroundwhile you still have forward motion (providedyou have the room to do so) and go down thehill.

POTENTIAL HAZImproperly crosshills. WHAT CAN HAPCould cause lossATV to overturn.HOW TO AVOID Never attempt toon any hill until turning techniquOwner’s Manualvery careful wheAvoid crossing tpossible.


7-27

When crossing the side of a hill: Always follow proper procedures as de-scribed in the Owner’s Manual.Avoid hills with excessively slippery orloose surfaces.Shift your weight to the uphill side of theATV.

brakes gradually, or dis-ediately on the uphill side.

WARNING

ARD ackwards or improper-hile climbing a hill.

PEN TV overturning. THE HAZARD r and maintain steadybing a hill. ward speed: phill.es.rking position “P” afterd.


7-28

If your ATV has stalled or stopped and youbelieve you can continue up the hill, restartcarefully to make sure you do not lift the frontwheels which could cause you to lose control.If you are unable to continue up the hill, dis-mount the ATV on the uphill side. Physicallyturn the ATV around and then descend thehill.

If you start to roll backwards, DO NOT applyeither brake abruptly. If you are in 2WD, applyonly the front brake. When this ATV is in 4WDor 4WD-LOCK, all wheels (front and rear) areinterconnected by the drive train. This meansthat applying either the front brake or the rearbrake will brake all wheels. When descendinghills, using either brake lever or the brake ped-al will brake the wheels on the downhill side.Avoid sudden application of either the front orrear brake because the wheels on the uphillside could come off the ground. The ATVcould easily tip over backwards. Apply both

the front and rear mount the ATV imm

POTENTIAL HAZStalling, rolling bly dismounting wWHAT CAN HAPCould result in AHOW TO AVOID Use proper geaspeed when climIf you lose all for

Keep weight uApply the brakShift to the payou are stoppe


7-29

If you begin rolling backwards: Keep weight uphill.2WD: Never apply the rear brakewhile rolling backwards. Apply thefront brake.4WD or 4WD-LOCK: Apply both frontand rear brakes gradually.When fully stopped, shift to the park-ing position “P”.

Dismount on uphill side or to a side ifpointed straight uphill. Turn the ATVaround and remount, following the pro-cedure described in the Owner’s Manu-al.

n 4WD or 4WD-LOCK, allear) are interconnected bymeans that applying eithere rear brake will brake all

cending hills, using eitherbrake pedal will brake thenhill side. Avoid sudden

the front or rear brake be-on the uphill side could

d. Apply both the front andlly.

, ride your ATV straightrp angles which could al-

ip or roll over. Carefullynd ride no faster than yout to obstacles which may


7-30

RIDING DOWNHILL When riding your ATV downhill, shift yourweight as far to the rear and uphill side of theATV as possible. Move back on the seat andsit with your arms straight. Engine compres-sion will do most of the braking for you. Formaximum engine compression braking effect,select low range “L” and change to 4WD or4WD-LOCK before beginning to descend thehill. Improper braking may cause a loss oftraction. Use caution while descending a hillwith loose or slippery surfaces. Braking abilityand traction may be adversely affected bythese surfaces. Improper braking may alsocause a loss of traction.

When this ATV is iwheels (front and rthe drive train. This the front brake or thwheels. When desbrake lever or the wheels on the dowapplication of eithercause the wheels come off the grounrear brakes gradua

Whenever possibledownhill. Avoid shalow the ATV to tchoose your path awill be able to reacappear.


7-31

WARNING

POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause theATV to overturn.Always follow proper procedures for go-ing down hills as described in this Own-er’s Manual. Note: a special technique isrequired when braking as you go downa hill. HOW TO AVOID THE HAZARD Always check the terrain carefully be-fore you start down any hill.Shift your weight backward.Never go down a hill at high speed.Avoid going down a hill at an angle thatwould cause the vehicle to lean sharplyto one side. Go straight down the hillwhere possible.

WARNING

ARD ing hills or turning on

PEN of control or cause the

THE HAZARD turn the ATV around

you have mastered thee as described in the on level ground. Ben turning on any hill.

he side of a steep hill if

he side of a hill: oper procedures as de-ner’s Manual.

excessively slippery orhift your weight to the

ATV.


7-32

CROSSING A SLOPE Traversing a sloping surface on your ATV re-quires you to properly position your weight tomaintain proper balance. Be sure that youhave learned the basic riding skills on flatground before attempting to cross a slopingsurface. Avoid slopes with slippery surfacesor rough terrain that may upset your balance.

As you travel across a slope, lean your bodyin the uphill direction. It may be necessary tocorrect the steering when riding on loose sur-faces by pointing the front wheels slightly up-hill. When riding on slopes be sure not tomake sharp turns either up or down hill.

If your ATV does begin to tip over, graduallysteer in the downhill direction if there are noobstacles in your path. As you regain properbalance, gradually steer again in the directionyou wish to travel.

POTENTIAL HAZImproperly crosshills. WHAT CAN HAPCould cause lossATV to overturn.HOW TO AVOID Never attempt toon any hill until turning techniquOwner’s Manualvery careful wheAvoid crossing tpossible. When crossing tAlways follow prscribed in the OwAvoid hills with loose surfaces. Suphill side of the


7-33

et brakes may have re-bility. Test your brakes

ter. If necessary, applyes to let friction dry out


7-34

CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving,shallow water of up to a maximum of 35 cm(14 inches) in depth. Before entering the wa-ter, choose your path carefully. Enter wherethere is no sharp drop off, and avoid rocks orother obstacles which may be slippery or up-set the ATV. Drive slowly and carefully.

WARNING

POTENTIAL HAZARD Operating this ATV through deep or fastflowing water. WHAT CAN HAPPEN Tires may float, causing loss of tractionand loss of control, which could lead toan accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowingwater or in water deeper than that spec-ified in your Owner’s Manual.

Remember that wduced stopping aafter leaving wathem several timthe linings.

ATV in water, be sure to water by removing thee bottom of the air filtereck hose on the V-belt

sh the ATV in fresh waterperated in salt water ors.

ose


7-35

Test your brakes after leaving the water. Donot continue to ride your ATV without verifyingthat you have regained proper braking ability.

CAUTION:_

After riding yourdrain the trappedcheck hose at thcase and the chcooling duct. Waif it has been omuddy condition_

1. Air filter case check h

heck hose


7-36

1. V-belt cooling duct check hose (Left side)

1. V-belt case drain plug

1. Drive select lever box c

WARNING

ZARD ating over obstacles. PEN

ss of control or a colli-se the ATV to overturn. THE HAZARD g in a new area, check

o ride over large obsta-ge rocks or fallen trees.er obstacles, always fol-edures as described in

nual.


7-37

RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done withcaution. Look out for obstacles which couldcause damage to the ATV or could lead to anupset or accident. Be sure to keep your feetfirmly mounted on the footboards at all times.Avoid jumping the ATV as loss of control anddamage to the ATV may result.

POTENTIAL HAImproperly operWHAT CAN HAPCould cause losion. Could cauHOW TO AVOIDBefore operatinfor obstacles.Never attempt tcles, such as larWhen you go ovlow proper procthe Owner’s Ma

of your ATV start to slidean usually be regained (ifso) by steering in the direc-plying the brakes or accel-mmended until you have


7-38

SLIDING AND SKIDDING Care should be used when riding on loose orslippery surfaces since the ATV may slide. Ifunexpected and uncorrected, sliding couldlead to an accident.

To reduce the tendency for the front wheels toslide in loose or slippery conditions, position-ing your weight over the front wheels willsometimes help.

If the rear wheels sideways, control cthere is room to do tion of the slide. Aperating is not recocorrected the slide.

WARNING

ZARD ing improperly. PEN ontrol of this ATV. You traction unexpectedly,e the ATV to overturn. THE HAZARD control skidding or slid-g at low speeds and onrrain.ppery surfaces, such asnd be very cautious in

the chance of skidding control.


7-39

With practice, over a period of time, skill atcontrolled sliding can be developed. The ter-rain should be chosen carefully before at-tempting such maneuvers, since both stabilityand control are reduced. Bear in mind thatsliding maneuvers should always be avoidedon extremely slippery surfaces such as ice,since all control may be lost.

POTENTIAL HASkidding or slidWHAT CAN HAPYou may lose cmay also regainwhich may causHOW TO AVOIDLearn to safely ing by practicinlevel, smooth teOn extremely sliice, go slowly aorder to reduceor sliding out of

s to slide sideways: tion of the slide if you haveg the brakes or accelerat-ended until you have cor-

(See pages 7-38–7-39.) t make it up a hill you are

ound if you still have for-ot, stop, dismount on the ATV and physically turn. If the ATV starts to slipNOT USE THE REARV may tip over on top ofe ATV on the uphill side.

–7-29.)


7-40

WHAT TO DO IF ... This section is designed to be a referenceguide only. Be sure to read each section onriding techniques completely.

WHAT TO DO ... � If your ATV doesn’t turn when you want it

to: Bring the ATV to a stop and practice theturning maneuvers again. Be sure you areputting your weight on the footboard to theoutside of the turn. Position your weightover the front wheels for better control.(See pages 7-22–7-23.)

� If your ATV begins to tip while turning: Lean more into the turn to regain balance. Ifnecessary, gradually let off the throttle and/or steer to the outside of the turn. (See pag-es 7-22–7-23.)

� If your ATV startSteer in the directhe room. Applyining is not recommrected the slide.

� If your ATV can’trying to climb: Turn the ATV arward speed. If nuphill side of thethe ATV aroundbackwards DO BRAKE - the ATyou. Dismount th(See pages 7-24



7-41

� If your ATV is traversing a sloping surface: Be sure to ride with your weight positionedtowards the uphill side of the ATV to main-tain proper balance. If the ATV starts to tip,steer down the hill (if there are no obstaclesin your way) to regain balance. If you dis-cover that the ATV is going to tip over, dis-mount on the uphill side. (See pages 7-32–7-33.)

� If your ATV encounters shallow water: Ride slowly and carefully through slowmoving water, watching for obstacles. Besure to let water drain from the ATV andCHECK YOUR BRAKES FOR PROPEROPERATION when you come out of thewater. Do not continue to ride your ATV un-til you have regained adequate brakingability. (See pages 7-34–7-36.)

WARNING_

Indicates a poteresult in serious

EBU00515

nd tool kitnded to put this owner’s bag and always carry it inut the owner’s tool kit andauge in the space beside

e

ealer perform service ifar with machine service.


8-1

PERIODIC MAINTENANCE AND ADJUSTMENT

Periodic inspection, adjustment and lubrica-tion will keep your machine in the safest andmost efficient condition possible. Safety is anobligation of the machine owner. The mostimportant points of machine inspection, ad-justment and lubrication are explained on thefollowing pages.

EBU00562

Owner’s manual aYou are recommemanual in the vinylthe storage box. Plow-pressure tire gthe battery.

1. Owner’s manual2. Owner’s tool kit3. Low-pressure tire gaug

WARNING

POTENTIAL HAZARDServicing an engine while it is running.WHAT CAN HAPPENMoving parts can catch clothing or partsof the body, causing injury.Electrical components can causeshocks or can start fires.HOW TO AVOID THE HAZARDTurn off the engine when performingmaintenance unless otherwise specified.

Have a Yamaha dyou are not famili

1

2

3

4

5

6

7

8

9

10

11

12

13

14

WARNING

ZARDTV with improper modi-

PENation of accessories orthis vehicle may causeling which in some situ-d to an accident. THE HAZARDis ATV through improp-r use of accessories. Allsories added to this ve-e genuine Yamaha orponents designed for and should be installedrding to instructions. Ifions, consult an autho-TV dealer.


8-2

The service information included in this man-ual is intended to provide you, the owner, withthe necessary information for completing yourown preventive maintenance and minor re-pairs. The tools provided in the Owner’s toolkit are sufficient for this purpose, except that atorque wrench is also necessary to properlytighten nuts and bolts.

NOTE:_

If you do not have a torque wrench availableduring a service operation requiring one, takeyour machine to a Yamaha dealer to checkthe torque settings and adjust them as neces-sary. _

POTENTIAL HAOperating this Afications.WHAT CAN HAPImproper installmodification of changes in handations could leaHOW TO AVOIDNever modify ther installation oparts and acceshicle should bequivalent comuse on this ATVand used accoyou have questrized Yamaha A

EBU00261

TIONINITIAL EVERY

750 (1,200)

1,500 (2,400)

1,500 (2,400)

3,000 (4,800)

75 150 150 300

Every 20–40 hoursore often in wet or dusty areas.)


8-3

PERIODIC MAINTENANCE/LUBRICA

ITEM ROUTINEWhichever comes first mile

(km)200

(320)hours 20

Valves* • Check valve clearance. • Adjust if necessary.

Cooling system• Check coolant leakage.• Repair if necessary.• Replace coolant every 24 months.

Spark plug• Check condition. • Adjust gap and clean.• Replace if necessary.

Air filter • Clean. • Replace if necessary. (M

Carburetor* • Check and adjust idle speed/starter operation.• Adjust if necessary.

Crankcase breather system*

• Check breather hose for cracks or damage.• Replace if necessary.

Exhaust system*• Check for leakage.• Retighten if necessary.• Replace gasket(s) if necessary.

Sparks arrester • Clean.

Fuel line* • Check fuel hose for cracks or damage.• Replace if necessary.

Engine oil • Replace (Warm engine before draining).Engine oil filter cartridge • Replace.Final gear oil • Check oil level/oil leakage.

• Replace.Differential gear oil

Front brake* • Check operation/fluid leakage/see NOTE page 8-4.• Correct if necessary.

Rear brake* • Check operation/fluid leakage/see NOTE page 8-4. • Correct if necessary.

V-belt* • Check operation. • Check for cracks or damage.

ealer.

oseness/damag

aged..

steners.

Whiccome

INITIAL EVERY )

750 (1,200)

1,500 (2,400)

1,500 (2,400)

3,000 (4,800)

75 150 150 300

ential hazard that could injury or death.


* It is recommended that these items be serviced by a Yamaha d** Lithium-soap-based grease

Wheels* • Check balance/damage/runout.• Repair if necessary.

Wheel bearing* • Check bearing assemblies for lo• Replace if damaged.

Front and rear suspension*

• Check operation.• Correct if necessary.

Steering system* • Check operation/Replace if dam• Check toe-in/Adjust if necessary

Rear upper and lower knuckle pivots* • Lubricate.**

Drive shaft universal joint* • Lubricate.**Engine mount* • Check for cracks or damage.

Front and rear axle boots* • Check operation.• Replace if damaged.

Stabilizer bushes* • Check for cracks or damage.

Fittings and Fasteners* • Check all chassis fittings and fa• Correct if necessary.

ITEM ROUTINE

NOTE:• Recommended brake fluid: DOT 4• Brake fluid replacement:1. When disassembling the master cylinder or c

per, replace the brake fluid. Normally check brake fluid level and add fluid as required.

2. On the inner parts of the master cylinder and iper, replace the oil seals every two years.

3. Replace the brake hoses every four years, ocracked or damaged.

8-4

ali-the

cal-

r if

WARNINGIndicates a potresult in serious

e.

hever s first mile

(km)200

(320hours 20

EBU00614

5. Panel E


8-5

Panel removal and installationThe panels illustrated need to be removed toperform some of the maintenance describedin this chapter.Refer to this section each time a panel has tobe removed or reinstalled.

1. Panel A 2. Panel C3. Panel B

4. Panel D6. Panel F


8-6

EBU00879

Panels A and DTo remove1. Remove the seat. (See page 4-20 for

seat removal and installation proce-dures.)

2. Pull outward on the area shown, andthen pull upward as shown.

1. Panel A

1. Panel D


8-7

To install1. Insert the panel projections in the numer-

ical order shown in the illustration, andthen push inward on the area shown.

2. Install the seat.

1. Panel A

1. Panel D

he panel, be sure not toor wires.


8-8

EBU00962

Panel BTo removeRemove the bolts.To installPlace the panel in the original position and in-stall the bolts.

1. Panel B 2. Bolt (× 2)

CAUTION:_

When installing tpinch the cables _

EBU01141


8-9

Panel CTo remove1. Remove the front carrier by removing the

stay covers at the rear, then by removingthe bolts.

2. Remove the quick fasteners and pull thepanel upward.

1. Front carrier stay cover (× 2)

1. Bolt (× 2)

1. Bolt (× 2)

nel in the original position quick fasteners.nt carrier by installing theening them to the specified

covers.

es: p): m·kgf, 19 ft·lbf) nder fenders):·kgf, 5.1 ft·lbf)


8-10

1. Bolt (× 2) (Under fenders)

1. Quick fastener (× 2) 2. Panel C

To install1. Place the pa

and install the2. Install the fro

bolts and tighttorques.

3. Install the stay

Tightening torquCarrier bolt (to

26 Nm (2.6 Carrier bolt (u

7 Nm (0.7 m

EBU01013 EBU00638

areas shown.


8-11

Panel ETo removeRemove the bolts, and then take the panel off.To installPlace the panel in the original position, andthen install the bolts.

1. Panel E 2. Bolt (× 6)

Panel FTo removePull outward on the

1. Panel F

easurementel F. (See page 8-11 foral and installation proce-

V on a level surface andngine for several minutes.e.ngine oil filler cap and wipe with a clean rag.tick in the filler hole without

2. Engine oil dipstick


8-12

To installPlace the panel in its original position.

EBU01099

Engine oilEngine oil level m1. Remove pan

panel removdures.)

2. Place the ATwarm up the e

3. Stop the engin4. Remove the e

off the dipstick5. Insert the dips

screwing it in.

1. Engine oil filler cap

l filter cartridge replace-

s E and F. (See page 8-11val and installation proce-

ngine for several minutes.e. Place an oil pan undercollect the used oil, ande engine oil filler cap.ain bolt and drain the oil.


8-13

NOTE:_

Wait a few minutes until the oil level settlesbefore checking. _

6. The oil level should be between the max-imum and minimum marks. If the level islow, fill the engine with sufficient oil toreach the specified level.

1. Maximum level mark 2. Minimum level mark

Engine oil and oiment1. Remove panel

for panel remodures.)

2. Warm up the e3. Stop the engin

the engine to then remove th

4. Remove the dr

1. Engine oil drain bolt

h is available at a nearby

in bolt and tighten it to theue.

e:

m·kgf, 22 ft·lbf)


8-14

5. Remove the oil filter cartridge by using anoil filter wrench.

1. Engine oil filter cartridge2. Oil filter wrench

NOTE:_

An oil filter wrencYamaha dealer. _

6. Install the draspecified torq

Tightening torquDrain bolt:

30 Nm (3.0

with sufficient oil to reachevel. Install the engine oilghten it.

ngine oil:.

p qt, 2.33 US qt)nge:p qt, 2.01 US qt)

rtridge replacement:p qt, 2.11 US qt)


8-15

1. Torque wrench

7. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge.

NOTE:_

Make sure the O-ring is seated properly. _

8. Install the oil filter cartridge, and thentighten it to the specified torque with atorque wrench.

9. Fill the enginethe specified lfiller cap and ti

Tightening torque:Oil filter cartridge:

17 Nm (1.7 m·kgf, 12 ft·lbf)

Recommended eSee page 10-2

Oil quantity:Total amount:

2.2 L (1.94 ImPeriodic oil cha

1.9 L (1.67 ImWith oil filter ca

2.0 L (1.76 Im

e must be checked for oilch ride. If any leakage isaha dealer check and re-

lacementhine on a level place.

ainer under the final geart the used oil.oil filler bolt and the draine oil.

olt


8-16

CAUTION:_

� In order to prevent clutch slippage(since the engine oil also lubricatesthe clutch), do not mix any chemicaladditives. Do not use oils with a dieselspecification of “CD” or oils of a high-er quality than specified. In addition,do not use oils labeled “ENERGYCONSERVING II” or higher.

� Make sure that no foreign material en-ters the crankcase.

_

10. Start the engine and warm it up for seve-ral minutes. While warming up, check foroil leakage. If oil leakage is found, stopthe engine immediately and check for thecause.

11. Install the panels.

EBU00880

Final gear oilThe final gear casleakage before eafound, have a Yampair the ATV.

Final gear oil rep1. Place the mac2. Place a cont

case to collec3. Remove the

bolt to drain th

1. Final gear case filler b

material enters the final

r bolt and tighten to thee.

leakage. If oil leakage isr the cause.

il:.

nge: Imp qt, 0.26 US qt)

Imp qt, 0.32 US qt)

: gear case): ·kgf, 16 ft·lbf)


8-17

1. Final gear oil drain bolt

4. Install the drain bolt and tighten it to thespecified torque.

5. Fill the final gear case with oil.

CAUTION:_

Be sure no foreigngear case. _

6. Install the fillespecified torqu

7. Check for oil found, check fo

Tightening torque: Drain bolt (final gear case):

23 Nm (2.3 m·kgf, 16 ft·lbf)

Recommended oSee page 10-3

Oil quantity: Periodic oil cha

0.25 L (0.22 Total amount:

0.30 L (0.26

Tightening torqueFiller bolt (final

23 Nm (2.3 m

iller bolt and tighten it to theue.

il replacementhine on a level place.iner under the differentialatch the oil.filler bolt and drain bolt to

oil drain bolt

e:

m·kgf, 16 ft·lbf)


8-18

EBU00706

Differential gear oilDifferential gear oil measurement1. Place the machine on a level place.2. Remove the oil filler bolt and check the oil

level. It should be up to the brim of thehole. If the level is low, add sufficient oil toraise it to the specified level.

1. Differential gear oil2. Differential gear case oil filler bolt3. Specified level

CAUTION:_

Be sure no foreign material enters the dif-ferential gear case. _

3. Install the oil fspecified torq

Differential gear o1. Place the mac2. Place a conta

gear case to c3. Remove the

drain the oil.

1. Differential gear case

Tightening torquOil filler bolt:

23 Nm (2.3

n material enters the dif-.

r bolt and tighten it to thee.leakage. If oil leakage isr the cause.


8-19

4. Install the drain bolt and tighten it to thespecified torque.

5. Fill the differential gear case with oil.

CAUTION:_

Be sure no foreigferential gear case_

6. Install the fillespecified torqu

7. Check for oil found, check fo

Tightening torque:Drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Recommended oil:SAE 80 API “GL-4” Hypoid gear oil

Oil quantity:Periodic oil change:

0.28 L (0.25 Imp qt, 0.3 US qt)Total amount:

0.33 L (0.29 Imp qt, 0.35 US qt)

coolant reservoir cap, andnt or distilled water to raise

ied level.lant reservoir cap.el.

lt water is harmful to theuse soft water if you can’tr.

ir capacity:p qt, 0.32 US qt)


8-20

EBU01068

Cooling system1. Check the coolant level in the coolant

reservoir when the engine is cold as thecoolant level will vary with engine tem-perature. The coolant level should be be-tween the maximum and minimummarks.

1. Coolant reservoir tank cap2. Maximum level mark 3. Minimum level mark

2. If the level is low, remove panel D. (Seepage 8-6 for panel removal and installa-tion procedures.)

3. Remove the then add coolait to the specif

4. Install the coo5. Install the pan

CAUTION:_

Hard water or saengine. You may get distilled wate_

Coolant reservo0.3 L (0.26 Im

EBU00887

lant

WARNING

ARD diator cap when the en- are still hot. PEN rned by hot fluid and

under pressure. THE HAZARD ine to cool before re-tor cap. Always use a

he cap. Allow any re-re to escape beforeving the cap.


8-21

NOTE:_

� If water is added, have a Yamaha dealercheck the antifreeze content of the cool-ant as soon as possible.

� The radiator fan operation is completelyautomatic. It is switched on or off accord-ing to the coolant temperature in the radi-ator.

_

If your ATV overheats, see page 8-56 for de-tails.

Changing the coo

POTENTIAL HAZRemoving the ragine and radiatorWHAT CAN HAPYou could be busteam blown outHOW TO AVOID Wait for the engmoving the radiathick rag over tmaining pressucompletely remo

front carrier and panel C.9 and 8-10 for removal andcedures.)


8-22

1. Place the ATV on a level surface.2. Remove panels E and F. (See page 8-11

for panel removal and installation proce-dures.)

3. Place a container under the engine, andthen remove the coolant drain bolt. (Usea trough or a similar object as shown toprevent coolant from spilling on the foot-rest.)

1. Coolant drain bolt

1. Trough

4. Remove the (See pages 8-installation pro

hose

the coolant, thoroughlyng system with clean tap

olant drain bolt washer if itnd then tighten the coolante specified torque.

:olt:·kgf, 7 ft·lbf)


8-23

1. Radiator cap

5. Remove the radiator cap.6. Remove the coolant reservoir cap.7. Disconnect the hose on the coolant res-

ervoir side, and then drain the coolantfrom the coolant reservoir.

1. Coolant reservoir drain

8. After drainingflush the cooliwater.

9. Replace the cois damaged, adrain bolt to th

Tightening torqueCoolant drain b

10 Nm (1.0 m

iator cap.ne and let it idle for severalp the engine, and thenlant level in the radiator. If itore coolant until it reachesradiator.t reservoir with coolant upm level.

oolant reservoir cap andlant leakage.

und, have a Yamaha deal-g system.

els and the front carrier.


8-24

10. Install the coolant reservoir hose.11. Pour the recommended coolant into the

radiator until it is full.

CAUTION:_

Hard water or salt water is harmful to theengine. You may use soft water if you cannot get distilled water. _

12. Install the rad13. Start the engi

minutes. Stocheck the coois low, add mthe top of the

14. Fill the coolanto the maximu

15. Install the ccheck for coo

NOTE:_

If any leakage is foer check the coolin_

16. Install the pan

Recommended antifreeze:High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines.

Antifreeze and water mixing ratio:1:1

Total amount:1.8 L (1.58 Imp qt, 1.90 US qt)

Coolant reservoir capacity (up to the maximum level mark):

0.3 L (0.26 Imp qt, 0.32 US qt)

EBU00862

h side)


8-25

Axle bootsCheck the protective boots for holes or tears.If any damage is found, have them replacedby a Yamaha dealer.

1. Front axle boot (× 2 each side)

1. Rear axle boot (× 2 eac


8-26

EBU00864

Spark plug inspectionRemoval 1. Remove panel A. (See pages 8-6–8-7 for

panel removal and installation proce-dures.)

2. Remove the spark plug cap.

1. Spark plug cap

3. Use the spark plug wrench in the tool kitto remove the spark plug as shown.

1. Spark plug wrench

lectrode gap with a wiree and, if necessary, adjust

cification.

ket surface. Wipe off any threads.k plug and tighten it to thee.

031–0.035 in)


8-27

Inspection The spark plug is an important engine compo-nent and is easy to inspect. The condition ofthe spark plug can indicate the condition ofthe engine. The ideal color on the white insu-lator around the center electrode is a medium-to-light tan color for a ATV that is being riddennormally. Do not attempt to diagnose suchproblems yourself. Instead, take the ATV to aYamaha dealer. You should periodically re-move and inspect the spark plug becauseheat and deposits will cause the spark plug toslowly break down and erode. If electrodeerosion becomes excessive, or if carbon andother deposits are excessive, you should re-place the spark plug with the specified plug.

Installation 1. Measure the e

thickness gaugthe gap to spe

a. Spark plug gap

2. Clean the gasgrime from the

3. Install the sparspecified torqu

Specified spark plug: DPR8EA-9 (NGK)

Spark plug gap: 0.8–0.9 mm (0.


8-28

NOTE:_

If a torque wrench is not available when youare installing a spark plug, a good estimate ofthe correct torque is 1/4 to 1/2 turn past fingertight. Have the spark plug tightened to thespecified torque as soon as possible. _

4. Install the spark plug cap.5. Install the panel.

Tightening torque: Spark plug:

17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)

EBU00792

2. Air filter case cover

r filter element and removee.


8-29

Air filter element cleaning

NOTE:_

There is a check hose at the bottom of the airfilter case. If dust or water collects in thishose, empty the hose and clean the air filterelement and air filter case. _

1. Air filter case check hose

1. Remove the seat. (See page 4-20 forseat removal procedure.)

2. Remove the air filter case cover by un-hooking the holders.

1. Holder (× 5)

3. Remove the aiit from its fram

1. Air filter element

xcess solvent out of the fil-d let it dry.

he filter element when

ment and replace it if dam-

WARNING

ZARD point solvents or gaso- air filter element.PEN

solvents or gasoline canlode. THE HAZARD ing solvent to clean the.


8-30

1. Air filter frame

4. Wash the element gently but thoroughlyin solvent. 5. Squeeze the e

ter element an

CAUTION:_

Do not twist tsqueezing it. _

6. Inspect the eleaged.

POTENTIAL HAUsing low flashline to clean theWHAT CAN HAPLow flash point catch fire or expHOW TO AVOIDUse parts cleanair filter element

t should be cleaned everyuld be cleaned and lubri-

the machine is operated inas. Each time the filter el-

e is performed, check theer case for obstructions.er rubber joint to the car-

old fittings for an airtightings securely to avoid theed air entering the engine.

engine with the air filter This will allow unfilteredg rapid engine wear and

amage. Additionally, op-e filter element will affect with subsequent poor possible engine over-


8-31

7. Apply Yamaha foam air filter oil or otherquality foam air filter oil to the element. Iffoam air filter oil is not available, motor oilmay be used.

NOTE:_

The element should be wet but not dripping. _

8. Pull the element over its frame.9. Install the element assembly.

1. Breather hose

10. Install the air filter case cover and be sureto connect the hose.

NOTE:_

The air filter elemen20–40 hours. It shocated more often if extremely dusty areement maintenancair inlet to the filtCheck the air cleanburetor and manifseal. Tighten all fittpossibility of unfilter_

CAUTION:_

Never operate theelement removed.air to enter, causinpossible engine deration without thcarburetor jettingperformance andheating. _

2. Spark arrester


8-32

EBU01066

Spark arrester cleaningBe sure the exhaust pipe and muffler are coolbefore cleaning the spark arrester.1. Remove the bolts.2. Remove the tailpipe by pulling it out of

the muffler.3. Tap the tailpipe lightly, and then use a

wire brush to remove any carbon depos-its from the spark arrester portion of thetailpipe.

4. Insert the tailpipe into the muffler andalign the bolt holes.

5. Install and tighten the bolts.

1. Bolt (× 3)

1. Tailpipe

EBU00874

t check hose llects in the V-belt coolingmove the hose and clean

ck hose (Left side)


8-33

V-belt cooling ducIf dust or water coduct check hose, reit.

1. V-belt cooling duct che

WARNING

POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust systemWHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poison-ing, possibly leading to death. Could start a fire.HOW TO AVOID THE HAZARD When cleaning the spark arrester:Always let the exhaust system cool pri-or to touching exhaust components. Do not start the engine when cleaningthe exhaust system.

tment vital part of the engine andisticated adjustment. Moste left to a Yamaha dealerssional knowledge and ex- However, the idling speed by the owner as a part ofnce routine.

as set at the Yamaha fac-tests. If the settings are

eone without sufficientdge, poor engine perfor-ge may result.


8-34

V-belt case drain plug After riding in water deep enough to allow it toenter the V-belt case, remove this plug todrain the water from the case.

NOTE:_

If water drains from the V-belt case after re-moving the plug, have a Yamaha dealer in-spect the ATV as the water may affect otherengine parts. _

1. V-belt case drain plug

EBU00296

Carburetor adjusThe carburetor is arequires very sophadjusting should bwho has the profeperience to do so.may be performedthe usual maintena

CAUTION:The carburetor wtory after many disturbed by somtechnical knowlemance and dama

EBU00657

l.

djustment clearance changes with

proper fuel/air supply orevent this, the valve clear-ted regularly. This adjust-

uld be left to a professionalhnician.


8-35

Idle speed adjustment

NOTE:A diagnostic tachometer must be used for thisprocedure.

1. Start the engine and warm it up for a fewminutes at approximately 1,000 to2,000 r/min. Occasionally rev the engineto 4,000 to 5,000 r/min. The engine iswarm when it quickly responds to thethrottle.

2. Remove panel D. (See pages 8-6 and 8-7for removal and installation procedures.)

3. Connect the tachometer and set the idleto the specified idling speed by adjustingthe throttle stop screw. Turn the screw into increase engine speed, and out to de-crease engine speed.

1. Throttle stop screw

4. Install the pane

EBU00303

Valve clearance aThe correct valveuse, resulting in imengine noise. To prance must be adjusment however, shoYamaha service tec

Specified idle speed:1,450–1,550 r/min

nspectionads for damage and wear.

less than the specified val-a dealer replace the pads.

a. Wear limit: 1 mm (0.04 in)

o be removed to inspect theage 8-45 for removal proce-


8-36

EBU00307

Throttle lever adjustment

NOTE:Adjust the engine idling speed before adjust-ing the throttle lever free play.

1. Loosen the locknut.2. Turn the adjusting bolt until the throttle le-

ver free play is 3–5 mm (0.12–0.20 in).3. Tighten the locknut.

1. Locknut 2. Adjusting bolta. Free play

EBU00312

Front brake pad iInspect the brake pIf the thickness is ue, have a Yamah

1. Brake pad

NOTE:The wheels need tbrake pads. See pdures.

EBU00878 EBU00875

ke fluid level luid may let air enter theibly causing the brakes to

. ck that the brake fluid isevel and replenish whenr brake fluid master cylin-ted behind panel B. (See

l removal and installation


8-37

Rear brake pad inspection Inspect the brake pads for damage and wear.If the thickness is less than the specified val-ue, have a Yamaha dealer replace the pads.

1. Brake pad 2. Brake pad platea. Wear limit: 1 mm (0.04 in)

Inspecting the braInsufficient brake fbrake system, possbecome ineffectiveBefore riding, cheabove the lower lnecessary. The reader reservoir is locapage 8-8 for paneprocedures.)

cautions: g the fluid level, make suremaster cylinder reservoir isg the handlebars.esignated quality brake flu- the rubber seals may dete-g leakage and poor brake

same type of brake fluid.may result in a harmful

tion and lead to poor brake

t water does not enter theer reservoir when refilling.nificantly lower the boilingid and may result in vapor

brake fluid: DOT 4


8-38

1. Minimum level mark

1. Minimum level mark

Observe these pre1. When checkin

the top of the level by turnin

2. Use only the did. Otherwise,riorate, causinperformance.

3. Refill with theMixing fluids chemical reacperformance.

4. Be careful thamaster cylindWater will sigpoint of the flulock.

FRONT

REAR

Recommended

EBU00623

tmenter should have a free playn) at the lever end. If not,ler to adjust it.


8-39

5. Brake fluid may deteriorate painted sur-faces or plastic parts. Always clean upspilled fluid immediately.

6. Have a Yamaha dealer check the causeif the brake fluid level goes down.

EBU01118

Brake fluid replacement 1. Complete fluid replacement should be

done only by trained Yamaha servicepersonnel.

2. Have a Yamaha dealer replace the fol-lowing components during periodic main-tenance or when they are damaged orleaking.

� Replace all rubber seals every two years. � Replace all hoses every four years.

Front brake adjusThe front brake levof zero mm (zero iask a Yamaha dea

a. Free play

and pedal adjustment free play adjustment er free play should be 0.5–n).cknut.

2. Adjusting bolt


8-40

EBU00963

Rear brake lever Rear brake lever The rear brake lev2 mm (0.02–0.08 i1. Loosen the lo

1. Locknutc. Free play

WARNING

POTENTIAL HAZARDOperating with improperly serviced oradjusted brakes.WHAT CAN HAPPENYou could lose braking ability, whichcould lead to an accident.HOW TO AVOID THE HAZARDAfter servicing:

� Make sure the brakes operatesmoothly and that the free play iscorrect.

� Make sure the brakes do not drag.� Make sure the brakes are not

spongy. All air must be bled fromthe brake system.

Replacement of brake components re-quires professional knowledge. Theseprocedures should be performed by aYamaha dealer.

height adjustment

ke before inspecting the

ke pedal should be posi- in) above the top of thea Yamaha dealer to adjust


8-41

2. Turn the adjusting bolt in direction a toincrease free play, and in direction b todecrease free play.

3. Tighten the locknut. If correct free play cannot be obtained, ask aYamaha dealer to make that adjustment.

NOTE:_

� When adjusting the rear brake lever freeplay:

� Be sure not to step on the brake pedal. � Make sure the brake pedal does not

move. _

Rear brake pedal

NOTE:_

Adjust the rear brarear brake pads. _

The top of the brationed 72 mm (2.8footrest. If not, ask it.

a. 72 mm (2.8 in)

r brake light switcht switch, which is activatedl and brake levers, is prop- the brake light comes on takes effect. If necessary,ht switch as follows. nut while holding the rearn place. To make the brakeer, turn the adjusting nut inke the brake light come on

sting nut in direction b.

h 2. Adjusting nut


8-42

EBU00834

Adjusting the reaThe rear brake lighby the brake pedaerly adjusted whenjust before brakingadjust the brake ligTurn the adjustingbrake light switch ilight come on earlidirection a. To malater, turn the adju

1. Rear brake light switc

WARNING

POTENTIAL HAZARD Operating with improperly serviced oradjusted brakes. WHAT CAN HAPPEN You could lose braking ability, whichcould lead to an accident. HOW TO AVOID THE HAZARD After servicing: � Make sure the brakes operate

smoothly and that the free play is cor-rect.

� Make sure the brakes do not drag. � All air must be bled from the brake

system. Replacement of brake components re-quires professional knowledge. Theseprocedures should be performed by aYamaha dealer.

EBU00356 EBU00717

rake pedal lubricationng parts.

bricant:ased grease ease)


8-43

Cable inspection and lubrication

Lubricate the inner cables and the cable ends.If the cables do not operate smoothly, ask aYamaha dealer to replace them.

Brake lever and bLubricate the pivotiWARNING

POTENTIAL HAZARDDamaged control cables.WHAT CAN HAPPENCorrosion can result when the outercovering of control cables becomesdamaged. Cables can also becomefrayed or kinked. Operation of controlscould be restricted, which could causean accident or injury.HOW TO AVOID THE HAZARDInspect cables frequently. Replace dam-aged cables.

Recommended lubricant:Yamaha chain and cable lube or SAE 10W30 motor oil

Recommended luLithium-soap-b(all-purpose gr

r and lower knuckle

er and lower wheel knuck-

2. Lower knuckle

lubricant: ased grease


8-44

EBU00877

Rear wheel uppelubrication Lubricate the upples.

1. Upper knuckle

Recommended Lithium-soap-b

EBU01112 EBU01121

el and the nuts.

are used for both the frontls. Install the nut with its ta-ards the wheel. k on the tire must pointting direction of the wheel.


8-45

Wheel removal1. Loosen the wheel nuts.2. Elevate the ATV and place a suitable

stand under the frame.3. Remove the nuts from the wheel.4. Remove the wheel.

1. Tapered nut (× 4)

Wheel installation1. Install the whe

NOTE:_

� Tapered nuts and rear wheepered side tow

� The arrow martoward the rota

_

1. Arrow mark


8-46

1. Tapered nut

2. Lower the ATV so that the wheel is on theground.

3. Tighten the wheel nuts to the specifiedtorque.

Wheel nut torque:Front: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf)

EBU00380

THE HAZARDith skin, eyes or cloth-ld eyes when working

eep out of reach of chil-

h with water. large quantities of wa-w with milk of magne- or vegetable oil. Getttention.

h water for 15 minutesedical attention. Keep

om sparks, flames, cig-ources of ignition. Ven-ing or using in a closed


8-47

BatteryThis machine is equipped with a sealed-typebattery. Therefore it is not necessary to checkthe electrolyte or add distilled water in the bat-tery. If the battery seems to have discharged,consult a Yamaha dealer.

CAUTION:Do not try to remove the sealing caps ofthe battery cells. You may damage the bat-tery.

WARNING

POTENTIAL HAZARDFailure to handle batteries or batteryelectrolyte carefully.WHAT CAN HAPPENYou could be poisoned. You could beseverely burned by the sulfuric acid inbattery electrolyte. Batteries produceexplosive gases.

HOW TO AVOID Avoid contact wing. Always shienear batteries. Kdren.Antidote:EXTERNAL: FlusINTERNAL: Drinkter or milk. Follosia, beaten eggprompt medical aEYES: Flush witand get prompt mbatteries away frarettes or other stilate when chargspace.


8-48

EBU00385

Battery maintenance1. When the machine is not used for a

month or longer, remove the battery andstore it in a cool, dark place. Completelyrecharge the battery before reinstallation.

CAUTION:A special battery charger (constant volt-age/ampere or constant voltage) is re-quired for recharging a sealed-typebattery. Using a conventional batterycharger may shorten the battery life.

2. Always make sure the connections arecorrect when putting the battery back inthe machine.

EBU00876

2. Spare fuse4. Ignition fuse6. Four-wheel drive fuse8. Odometer fuse (Backup)

30A 15A 10A

ck fuse: 10A e fuse: 3A m fuse: 10A (backup): 10A


8-49

Fuse replacement 1. The main fuse case and the fuse box are

located under the seat.2. If a fuse is blown, turn off the main switch

and install a new fuse of the specifiedamperage. Then turn on the switches. Ifthe fuse immediately blows again, con-sult a Yamaha dealer.

1. Main fuse3. Headlight fuse5. Auxiliary DC jack fuse7. Signaling system fuse9. Spare fuse (× 3)

Specified fuses: Main fuse:Headlight fuse:Ignition fuse:Auxiliary DC jaFour-wheel drivSignaling systeOdometer fuse


8-50

CAUTION:_

To prevent accidental short-circuiting,turn off the main switch when checking orreplacing a fuse. _

WARNING

POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage tothe electrical system which could leadto a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rat-ing. Never use a material in place of theproper fuse.

EBU01125

headlight bulb holder byerclockwise.


8-51

Replacing a headlight bulbIf a headlight bulb burns out, replace it as fol-lows.1. Remove the bulb holder cover at the rear

of the headlight by pulling it off.

1. Cover

1. Bulb holder cover

2. Remove the turning it count

1. Bulb holder

djustment

have a Yamaha dealerent.

, turn the adjusting screw in

, turn the adjusting screw in

ting screw


8-52

3. Remove the defective bulb by pushing itin and turning it counterclockwise.

4. Insert a new headlight bulb into the bulbholder, push it in, and then turn it clock-wise until it stops.

5. Install the bulb holder by turning it clock-wise.

6. Install the bulb holder cover at the rear ofthe headlight.

EBU01089

Headlight beam a

CAUTION:_

It is advisable tomake this adjustm_

To raise the beamdirection a.To lower the beamdirection b.

1. Headlight beam adjus

WARNING

POTENTIAL HAZARD A headlight bulb is hot when it is on andimmediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could startif the bulb touches something flamma-ble. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touchingor removing it.

EBU01105


8-53

Tail/brake light bulb replacementIf the tail/brake light bulb burns out, have aYamaha dealer replace it.

WARNING

ZARDel system while smok-

pen flame.PEN

or explode, causing se-operty damage. THE HAZARDwhen checking the fuelure there are no opens in the area, including water heaters or furnac-


8-54

EBU00412

TroubleshootingAlthough Yamaha machines receive a rigid in-spection before shipment from the factory,trouble may occur during operation. Any prob-lem in the fuel, compression, or ignition sys-tems can cause poor starting and loss ofpower. The troubleshooting chart describes aquick, easy procedure for making checks. Ifyour machine requires any repair, take it to aYamaha dealer.The skilled technicians at a Yamaha dealer-ship have the tools, experience, and know-how to properly service your machine. Useonly genuine Yamaha parts on your machine.Imitation parts may look like Yamaha parts,but they are often inferior. Consequently, theyhave a shorter service life and can lead to ex-pensive repair bills.

POTENTIAL HAChecking the fuing or near an oWHAT CAN HAPFuel can ignite vere injury or prHOW TO AVOIDDo not smoke system. Make sflames or sparkpilot lights fromes.

EBU00806

No fuel. Fuel cock isclogged.

Clean the fuel cock.

k is good.Ignition system isnormal.

is weak.

Adjust the spark plug gapor replace the spark plug.

park.

amaha dealer tot.

ock


8-55

Troubleshooting chartsStarting problems or poor engine performance

1. Fuel

Check if there is fuelin the fuel tank.

There is fuel. Turn the fuel cocklever to “OFF”.

Some fuel. Turn the fuel cocklever to “RES”.

Restart the engine.

No fuel. Supply fuel.

2. Compression

Use the electricstarter to see if there is compression.

There is compression. Compression normal.

No compression. Ask a Yamaha dealer toinspect.

3. Ignition

Remove the spark plug and check the electrodes.

Wet Wipe clean with dry cloth.

DryAttach spark plug cap andground to chassis.

Use theelectric starter.

Spar

Spark

No s

Ask a Yinspec

4. Battery

Use the electric starter.

Engine turns overquickly. Battery is good.

Engine turns overslowly. Check the connections.

Check the fuel flow.

Turn the fuel clever to “ON”.

Remove the fuel hosefrom the fuel cock.

porarily used, provided that

THE HAZARD gine to cool before re-iator cap. Always use athe cap. Allow any re-ure to escape before

ving the cap.

ge.

age.Ask a Yamaha dealer to inspect and repair the cooling system.

Add coolant. (See NOTE.)

e. If the engine overheats again, ask a o inspect and/or repair the cooling system.


8-56

Engine overheating

NOTE:_

If it is difficult to get the recommended coolant, tap water can be temit is changed to the recommended coolant as soon as possible. _

WARNING

POTENTIAL HAZARD Removing the radiator cap when the en-gine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid andsteam blown out under pressure.

HOW TO AVOIDWait for the enmoving the radthick rag over maining presscompletely remo

Wait until the engine has cooled.

Check the coolant level in the reservoir tank and/or radiator.

Level is OK.

Level is low, check the cooling system for leakage.

No leaka

Leak

Restart the enginYamaha dealer t

EBU00419

ressure may cause wa- deterioration of wheel transmission seals and. Many expensive repaird from improper high

nt applications such ascoin-operated car wash-

ority of the dirt has beenh all surfaces with warm, detergent-type soap. An

or bottle brush is handy forplaces.hine off immediately withd dry all surfaces with a

n towel or soft absorbent


9-1

CLEANING AND STORAGE

A. CLEANINGFrequent, thorough cleaning of your machinewill not only enhance its appearance but willimprove its general performance and extendthe useful life of many components.1. Before cleaning the machine:a. Block off the end of the exhaust pipe to

prevent water entry. A plastic bag andstrong rubber band may be used.

b. Make sure the spark plug and all fillercaps are properly installed.

2. If the engine case is excessively greasy,apply degreaser with a paint brush. Donot apply degreaser to the wheel axles.

3. Rinse the dirt and degreaser off with agarden hose. Use only enough pressureto do the job.

CAUTION:¯

Excessive water pter seepage andbearings, brakes,electrical devicesbills have resultepressure detergethose available in ers.

4. Once the majhosed off, waswater and mildold toothbrushhard-to-get-at

5. Rinse the macclean water anchamois, cleacloth.

1

2

3

4

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6

7

8

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10

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14

WARNING

ZARDwet brakes after wash-

PEN have reduced stoppingg the chance of an acci-

THE HAZARDafter washing. Apply thetimes at slow speeds tout the linings.


9-2

6. Clean the seat with a vinyl upholsterycleaner to keep the cover pliable andglossy.

7. Automotive type wax may be applied toall painted and chrome plated surfaces.Avoid combination cleaner-waxes. Manycontain abrasives which may mar thepaint or protective finish. When finished,start the engine and let it idle for severalminutes.

POTENTIAL HAOperation with ing.WHAT CAN HAPWet brakes mayability, increasindent.HOW TO AVOIDTest the brakes brakes several let friction dry o

EBU00530

park plug, pour about one SAE 10W30 or 20W40 spark plug hole and rein- plug. Ground the spark

turn the engine over seve-t the cylinder wall with oil.ntrol cables.ame to raise all wheels off

ag over the exhaust pipent moisture from entering. humid or salt-air atmo-ll exposed metal surfaces of oil. Do not apply oil tots or the seat cover.


9-3

B. STORAGELong term storage (60 days or more) of yourmachine will require some preventive proce-dures to guard against deterioration. Afterthoroughly cleaning the machine, prepare forstorage as follows:1. Fill the fuel tank with fresh fuel and add

the specified amount of Yamaha FuelStabilizer and Conditioner or an equiva-lent product.

NOTE:Use of fuel stabilizer and conditioner elimi-nates the need to drain the fuel system. Con-sult a Yamaha dealer if the fuel system needsto be drained instead.

2. Remove the stablespoon ofmotor oil in thestall the sparkplug wire and ral times to coa

3. Lubricate all co4. Block up the fr

the ground.5. Tie a plastic b

outlet to preve6. If storing in a

sphere, coat awith a light filmany rubber par

Specified amount:1 oz of stabilizer to each gallon of fuel (or 7.5 cc of stabilizer to each liter of fuel)


9-4

7. Remove the battery and charge it. Storeit in a dry place and recharge it once amonth. Do not store the battery in an ex-cessively warm or cold place (less than0 °C (30 °F) or more than 30 °C (90 °F)).

NOTE:Make any necessary repairs before storingthe machine.

EBU00428

FM660F

SOHC

cylinder

.31 in)

er


10-1

SPECIFICATIONS

Model Y

Dimensions:Overall length 2,085 mm (82.1 in)

Overall width 1,150 mm (45.3 in)

Overall height 1,210 mm (47.6 in)Seat height 880 mm (34.6 in)

Wheelbase 1,275 mm (50.2 in)

Minimum ground clearance 275 mm (10.8 in)Minimum turning radius 3,200 mm (126.0 in)

Basic weight:

With oil and full fuel tank 290 kg (639 lb)Engine:

Engine type Liquid-cooled 4-stroke,

Cylinder arrangement Forward-inclined singleDisplacement 660 cm3

Bore × stroke 100 × 84 mm (3.94 × 3

Compression ratio 9.1 :1Starting system Electric and recoil start

Lubrication system Wet sump

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2

3

4

5

6

7

8

9

10

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12

13

14

50° 70° 90° 110° 130°F

10° 20° 30° 40° 50°C

MALUBE 4 (20W40) or SAE 20W40

4 (10W30) or SAE 10W30

G type or higher

1 US qt)

1 US qt)3 US qt)

YFM660F

utch slippage (since the en-s the clutch), do not mix anyo not use oils with a diesel or oils of a higher qualityition, do not use oils labeledNG II” or higher.


10-2

Engine oil:Type 10° 30°0°

-10° 0°-20°

YA

YAMALUBE

SAE 5W30

Recommended engine oil classification API Service SE, SF, S

Quantity:

Periodic oil change 1.9 L (1.67 Imp qt, 2.0

With oil filter replacement 2.0 L (1.76 Imp qt, 2.1Total amount 2.2 L (1.94 Imp qt, 2.3

Model

CAUTION:In order to prevent clgine oil also lubricatechemical additives. Dspecification of “CD”than specified. In add“ENERGY CONSERVI

oid gear oil

6 US qt)

2 US qt)

oid gear oil

0 US qt)5 US qt)

E ONLY

US gal)

2 US gal)

FM660F


10-3

Final gear case oil:

Type SAE80 API “GL-4” Hyp

Quantity:Periodic oil change 0.25 L (0.22 Imp qt, 0.2

Total amount 0.30 L (0.26 Imp qt, 0.3

Differential gear case oil:Type SAE80 API “GL-4” Hyp

Quantity:

Periodic oil change 0.28 L (0.25 Imp qt, 0.3Total amount 0.33 L (0.29 Imp qt, 0.3

Air filter: Wet type element

Fuel:Type UNLEADED GASOLIN

Fuel tank capacity 20 L (4.40 lmp gal, 5.28

Fuel reserve amount 3.5 L (0.77 lmp gal, 0.9Carburetor:

Type / quantity BSR42 / 1

Manufacturer MIKUNI

Model Y

035 in)atic

7.944)

YFM660F


10-4

Spark plug:

Type/manufacturer DPR8EA-9 / NGK

Spark plug gap 0.8–0.9 mm (0.031–0.Clutch type Wet, centrifugal autom

Transmission:

Primary reduction system V-beltSecondary reduction system Shaft drive

Secondary reduction ratio 39/24 × 24/18 × 33/9 (

Transmission type V-belt automaticOperation Left hand operation

Reverse gear 25/17 (1.471)

Sub transmission ratio low 37/15 (2.466)high 28/19 (1.473)

Chassis:

Frame type Steel tube frameCaster angle 5°

Trail 26 mm (1.02 in)

Tire:Type Tubeless

Size front AT25 × 8 - 12

rear AT25 × 10 - 12

Model

t operation

FM660F


10-5

Brake:

Front brake type Dual disc brake

operation Right hand operationRear brake type Single disc brake

operation Left hand and right foo

Suspension:Front suspension Double wishbone

Rear suspension Double wishbone

Shock absorber:Front shock absorber Coil spring / oil damper

Rear shock absorber Coil spring / oil damper

Wheel travel:Front wheel travel 170 mm (6.69 in)

Rear wheel travel 225 mm (8.86 in)

Electrical:Ignition system DC. C.D.I.

Generator system A.C. magneto

Battery type YTX20L-BSBattery capacity 12 V, 18 Ah

Headlight type: Krypton bulb

Model Y

YFM660F


10-6

Bulb voltage, wattage × quantity:

Headlight 12 V, 30 W / 30 W × 2

Tail/brake light 12 V, 5 W / 21 W × 1Indicator light:

Neutral indicator light LED × 1

Reverse indicator light LED × 1Coolant temperature warning light LED × 1

Park indicator light LED × 1

High-range indicator light LED × 1Low-range indicator light LED × 1

Differential gear lock indicator light LED × 1

Specified fuses: Main fuse 30A

Headlight fuse 15A

Ignition fuse 10AAuxiliary DC jack fuse 10A

Four-wheel drive fuse 3A

Signaling system fuse 10AOdometer fuse (backup) 10A

Model

11-1

EBU00430

1-NOISE REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop-erative by any person other than for purposes of maintenance, repair, or replacement of any de-vice or element of design incorporated into any new vehicle for the purpose of noise control priorto its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle aftersuch device or element of design has been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTEDBELOW.”These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust systemMufflerExhaust pipeSilencer

Intake systemAir cleaner caseAir cleaner elementIntake duct


12-1

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EBU01126

1-MAINTENANCE RECORD

Copies of work orders and/or receipts for parts you purchase and install will be required to docu-ment maintenance done in accordance with the warranty. The chart below is printed only as a re-minder to you that the maintenance work is required. It is not acceptable proof of maintenancework.ACL-02EACL-02E

MAINTENANCEINTERVAL

DATE OFSERVICE

MILEAGESERVICING DEALER

NAME AND ADDRESSREMARKS

200 mi (320 km) or 20 hours

750 mi (1,200 km) or 75 hours

1,500 mi (2,400 km) or 150 hours

3,000 mi (4,800 km) or 300 hours

4,500 mi (7,200 km) or 450 hours

6,000 mi (9,600 km) or 600 hours

7,500 mi (12,000 km) or 750 hours

9,000 mi (14,400 km) or 900 hours

10,500 mi (16,800 km) or 1,050 hours

12,000 mi (19,200 km) or 1,200 hours

13,500 mi (21,600 km) or 1,350 hours

15,000 mi (24,000 km) or 1,500 hours


EBU00432

.


13-1

YAMAHA MOTOR CORPORATION, U.S.AATV LIMITED WARRANTY

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13-2

EBU00435


14-1

YAMAHA EXTENDED SERVICE (Y.E.S.)

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14-2

EBU00436

WARNING_

Indicates a poteresult in serious


EBU00437

EBU00776

5KM-28199-11LIT-11626-16-34

READ THIS MANUAL CAREFULLY!It contains important safety information.

This ATV should not be ridden by anyone under 16 years of age.WARNING

YFM660FR

OWNER’S MANUAL

PRINTED IN JAPAN2002.06-7.8×1 CR

(E)

PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.

EBU00438

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.(For replacement manual, call 1-800-532-1558)

WARNING

ALWAYS: 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.

Improper ATV use can result in SEVERE INJURY or DEATH.

NEVER operate: without proper training or instruction. at speeds too fast for your skills or the conditions. on public roads-a collision can occur with another vehicle. with a passenger-passengers affect balance and steering and increase risk of losing control.

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

B EE R

B EE R

Card.fm Page 1 Wednesday, June 13, 2001 9:35 AM

Card.fm Page 2 Wednesday, June 13, 2001 9:35 AM

Documents

Grizzly 660 - Yamaha Motor Company · LIT-11626-16-34 5KM-28199-11 READ THIS MANUAL CAREFULLY! It contains important safety information. WARNING This ATV should not be ridden by anyone