yfz_450

OWNER’S MANUAL

READ THIS MANUAL CAREFULLY!It contains important safety information.

w

LIT-11626-19-32 5TG-28199-12

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

YFZ450V

5TG-9-12 hyoshi 5/12/05 3:16 PM Page 1

Downloaded from www.Manualslib.com manuals search engine

http://www.manualslib.com/

5TG-9-12 hyoshi 5/12/05 3:16 PM Page 2



EBU13320

INTRODUCTIONCongratulations on your purchase of the Yamaha YFZ450V. It represents the result of many years ofYamaha experience in the production of fine sporting, touring, and pacesetting racing machines. Withthe purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliabilitythat have made Yamaha a leader in these fields.This manual will provide you with a good basic understanding of the features and operation of this ATV.This manual includes important safety information. It provides information about special tech-niques and skills necessary to ride your ATV.It also includes basic maintenance and inspection procedures.If you have any questions regarding the operation or maintenance of your ATV, please consult aYamaha dealer.AN IMPORTANT SAFETY MESSAGE:8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM-

PLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUC-TIONS.

8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.8 NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING

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

8 THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER16 YEARS OF AGE.

8 THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT TYPERECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.

5TG-9-12-1 4/30/05 11:15 AM Page 1



EBU08010

IMPORTANT MANUAL INFORMATIONFAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERI-OUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

w Failure to follow WARNING instructions could result in severe injury or deathto the machine operator, a bystander or a person inspecting or repairing themachine.

cC A CAUTION indicates special precautions that must be taken to avoiddamage to the machine.

NOTE: A NOTE provides key information to make procedures easier or clearer.

5TG-9-12-1 4/30/05 11:15 AM Page 2



EBU15000

IMPORTANT NOTICEThis ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operatethis ATV on any public street, road or highway.This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulationsin effect at the time of manufacture.Please check your local riding laws and regulations before operating this ATV.

EBU13330

AFFIX DEALERLABEL HERE

YFZ450VOWNER’S MANUAL

©2005 by Yamaha Motor Corporation, U.S.A.

1st edition, May 2005All rights 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-11626-19-32

5TG-9-12-1 4/30/05 11:15 AM Page 3



EBU00140

wIndicates a potential hazard that could resultin serious injury or death.

CONTENTS

LOCATION OF THE WARNING ANDSPECIFICATION LABELS ................... 1-1

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

DESCRIPTION AND MACHINE IDENTIFI-CATION ................................................ 3-1

Identification number records ............. 3-2Key identification number ................... 3-2Vehicle identification number ............. 3-3Model label ......................................... 3-3

CONTROL FUNCTIONS ...................... 4-1Main switch ......................................... 4-1Indicator and warning lights ................ 4-2Handlebar switches ............................ 4-4Throttle lever ...................................... 4-5Speed limiter ...................................... 4-6Clutch lever ........................................ 4-7Brake lever ......................................... 4-7Brake pedal ........................................ 4-8Parking brake lever ............................ 4-9Shift pedal ........................................ 4-10Fuel tank cap .................................... 4-11Fuel cock ........................................... 4-11Starter (choke)................................... 4-12Seat .................................................. 4-13Front shock absorber adjustment ..... 4-14Rear shock absorber adjustment ..... 4-18

1

2

3

4

5TG-9-12-1 4/30/05 11:15 AM Page 4



PRE-OPERATION CHECKS ................ 5-1Front and rear brakes ......................... 5-3Fuel .................................................... 5-4Engine oil ............................................ 5-6Coolant ............................................... 5-7Chain .................................................. 5-8Throttle lever ...................................... 5-8Tires ................................................... 5-8How to measure tire pressure ............ 5-9Tire wear limit ................................... 5-10Fittings and fasteners ....................... 5-11Lights ................................................ 5-11Switches ........................................... 5-11

OPERATION ........................................ 6-1Starting a cold engine ......................... 6-1Starting the warm engine ................... 6-4Warming up ........................................ 6-4Shifting ............................................... 6-4To start out and accelerate: ................ 6-6To decelerate: .................................... 6-7

Engine break-in .................................. 6-7Parking ............................................... 6-8Parking on a slope .............................. 6-9Accessories and loading .................. 6-10

RIDING YOUR ATV .............................. 7-1GETTING TO KNOW YOUR ATV ...... 7-3RIDE WITH CARE AND GOOD

JUDGEMENT ................................... 7-4BE CAREFUL WHERE YOU RIDE .. 7-16TURNING YOUR ATV ...................... 7-23CLIMBING UPHILL .......................... 7-25RIDING DOWNHILL ......................... 7-30CROSSING A SLOPE ...................... 7-32CROSSING THROUGH SHALLOW

WATER .......................................... 7-34RIDING OVER ROUGH TERRAIN ... 7-36SLIDING AND SKIDDING ................ 7-38WHAT TO DO IF ... .......................... 7-40WHAT TO DO ... .............................. 7-40

5

6

7

5TG-9-12-1 4/30/05 11:15 AM Page 5



PERIODIC MAINTENANCE AND ADJUSTMENT ....................................8-1Owner’s manual and tool kit .................8-1Periodic maintenance chart for the emission control system .................... 8-3

General maintenance and lubrication chart ................................................... 8-4

Panel removal and installation ............. 8-7Engine oil and oil filter element ............ 8-9Cooling system .................................. 8-15Changing the coolant ......................... 8-16Spark plug inspection ........................ 8-19Air filter element cleaning .................. 8-25Spark arrester cleaning ...................... 8-28Carburetor adjustment ....................... 8-30Idle speed adjustment ........................ 8-31Valve clearance adjustment ............... 8-31Throttle lever adjustment ................... 8-32Front and rear brake pad inspection ..... 8-32Brake fluid level inspection ................ 8-34Brake fluid replacement ..................... 8-36Front brake lever free play ................. 8-37Brake pedal height adjustment .......... 8-38

Parking brake adjustment ................. 8-39Adjusting the rear brake light switch .... 8-41Clutch lever free play adjustment ..... 8-41Drive chain slack check .................... 8-43Adjusting the drive chain slack ......... 8-44Lubricating the drive chain ............... 8-45Cable inspection and lubrication ...... 8-47Brake and shift pedal/brake and clutch lever lubrication .................... 8-48

Front upper and lower arm pivot lubrication ....................................... 8-49

Rear arm pivot lubrication ................ 8-50Wheel removal ................................. 8-51Wheel installation ............................. 8-52Battery .............................................. 8-53Battery maintenance ........................ 8-54Fuse replacement ............................. 8-55Replacing a headlight bulb ............... 8-56Headlight beam adjustment .............. 8-59Tail/brake light .................................. 8-59Troubleshooting ................................ 8-60Troubleshooting charts ..................... 8-61

8

5TG-9-12-1 4/30/05 11:15 AM Page 6



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

10

11

12

13

14

5TG-9-12-1 4/30/05 11:15 AM Page 7



1-1

EBU04640

LOCATION OF THE WARNING AND SPECIFICATION LABELS

5TG-9-12-1 4/30/05 11:15 AM Page 1-1



Read and understand all of the labels on yourmachine. They contain important information forsafe 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.

1-2

q

w

5FE-21568-01

1

5FE-21697-01

5TG-9-12-1 4/30/05 11:15 AM Page 1-2



1-3

r

t

y

qWARNINGNEVER ride as a

passenger.Passengers can cause a loss of control,resulting in SEVEREINJURY or DEATH.

5FE-2151H-405FE-2151H-01

e

PREMIUM UNLEADED GASOLINE ONLY91 Min. Pump Octane (R+M) 2

5PW-2415E-11

5TG-9-12-1 4/30/05 11:15 AM Page 1-3



2-1

EBU13381

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollovercan occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles,if you fail to take proper precautions.SEVERE INJURY OR DEATH can result if you do not follow these instructions:8 Read this manual and all labels carefully and follow the operating procedures described.8 Never operate an ATV without proper training or instruction. Take a Training Course.Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call1-800-887-2887 to find out about the training courses nearest you.8 Always follow the age recommendation:- A child under 16 years old should never operate an ATV with engine size greater than 90cc.8 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow con-

tinued use of an ATV by a child if he or she does not have the abilities to operate it safely.8 Never carry a passenger on an ATV.

q SAFETY INFORMATION2

5TG-9-12-1 4/30/05 11:15 AM Page 2-1



2-2

8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lotsand streets.

8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one.8 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You

should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or ajacket, and long pants.

8 Never consume alcohol or drugs before or while operating this ATV.8 Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is prop-

er for the terrain, visibility, operating conditions, and your experience.8 Never attempt wheelies, jumps, or other stunts.8 Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always

follow the inspection and maintenance procedures and schedules described in this manual.8 Always keep both hands on the handlebars and both feet on the footpegs of the ATV during opera-

tion.8 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to

changing terrain conditions when operating the ATV.8 Never operate on excessively rough, slippery or loose terrain until you have learned and practiced

the skills necessary to control the ATV on such terrain. Always be especially cautious on thesekinds of terrain.

5TG-9-12-1 4/30/05 11:15 AM Page 2-2



2-3

8 Always follow proper procedures for turning as described in this manual. Practice turning at lowspeeds before attempting to turn at faster speeds. Do not turn at excessive speed.

8 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hillsbefore attempting larger hills.

8 Always follow proper procedures for climbing hills as described in this manual. Check the terraincarefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Nevergo over the top of a hill at high speed.

8 Always follow proper procedures for going down hills and for braking on hills as described in thismanual. Check the terrain carefully before you start down any hill. Shift your weight backward.Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicleto lean sharply to one side. Go straight down the hill where possible.

8 Always follow proper procedures for crossing the side of a hill as described in this manual. Avoidhills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.Never attempt to turn the ATV around on any hill until you have mastered the turning techniquedescribed in this manual on level ground. Avoid crossing the side of a steep hill if possible.

5TG-9-12-1 4/30/05 11:15 AM Page 2-3



2-4

8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling,use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards,follow the special procedure for braking described in this manual. Dismount on the uphill side or to aside if pointed straight uphill. Turn the ATV around and remount, following the procedure describedin this manual.

8 Always check for obstacles before operating in a new area.Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always followproper procedures when operating over obstacles as described in this manual.

8 Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicingat low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowlyand be very cautious in order to reduce the chance of skidding or sliding out of control.

8 Never operate an ATV in fast flowing water or in water deeper than that recommended in this manu-al. Remember that wet brakes may have reduced stopping ability. Test your brakes after leavingwater. If necessary, apply them several times to let friction dry out the linings.

5TG-9-12-1 4/30/05 11:15 AM Page 2-4



2-5

8 Always use the size and type of tires specified in this manual.8 Always maintain proper tire pressure as described in this manual.8 Never modify an ATV through improper installation or use of accessories.8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and

securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pullinga trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commissionat 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.

5TG-9-12-1 4/30/05 11:15 AM Page 2-5



2-6

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could beburned.

HOW TO AVOID THE HAZARD

Always turn off the engine when refueling.Do not refuel immediately after the enginehas been running and is still very hot. Donot spill gasoline on the engine or exhaustpipe/muffler when refueling. Never refuelwhile smoking or in the vicinity of sparks,open flames, or other sources of ignitionsuch as the pilot lights of water heatersand clothes dryers.

qWARNING When transporting the ATV in anothervehicle, be sure it is kept upright and thatthe fuel cock is in the “OFF” position.Otherwise, fuel may leak out of the carbu-retor or fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can causeinjuries.


If you should swallow some gasoline orinhale a lot of gasoline vapor, or get somegasoline in your eyes, see your doctorimmediately.If gasoline spills on your skin, wash withsoap and water. If gasoline spills on yourclothing, change your clothes.

5TG-9-12-1 4/30/05 11:15 AM Page 2-6



2-7

POTENTIAL HAZARD

Starting or running the engine in a closedarea.

WHAT CAN HAPPEN

Exhaust fumes are poisonous and maycause loss of consciousness and deathwithin a short time.


Always operate your ATV in an area withadequate ventilation.

qWARNING

5TG-9-12-1 4/30/05 11:15 AM Page 2-7



3-1

EBU00320

1. Spark arrester 12. Tail/brake light2. Seat 13. Coolant reservoir3. Fuel tank cap 14. Shift pedal4. Radiator cap 15. Engine oil tank5. Oil filter element 16. Clutch lever6. Brake pedal 17 Handlebar switches7. Headlights 18. Parking brake lever8. Fuel cock 19. Main switch9. Starter (choke) 20. Throttle lever

10. Throttle stop screw 21. Brake lever11. Fuse

NOTE:The machine you have purchased may differslightly from those shown in the figures of thismanual.

DESCRIPTION AND MACHINE IDENTIFICATION

5TG-9-12-1 4/30/05 11:15 AM Page 3-1



EBU06000

Identification number recordsRecord the key identification number, vehicleidentification number and model label informa-tion in the spaces provided for assistance whenordering spare parts from a Yamaha dealer orfor reference in case the vehicle is stolen.1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUMBER:

3. MODEL LABEL INFORMATION:

EBU00350

Key identification numberThe key identification number is stamped on thekey as shown in the following illustration. Thisnumber can be used for ordering a new key.

1. Key identification number

3-2

1

6

3

5TG-9-12-1 4/30/05 11:15 AM Page 3-2



EBU00360

Vehicle identification numberThe vehicle identification number is stampedinto the frame.

1. Vehicle identification number

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

EBU07870

Model labelThe model label is affixed to the location in theillustration. Record the information on this labelin the space provided. This information will beneeded to order spare parts from your Yamahadealer.

1. Model label

3-3

5TG-9-12-1 4/30/05 11:15 AM Page 3-3



EBU00390

CONTROL FUNCTIONSw

Indicates a potential hazard that could resultin serious injury or death.

EBU00420

Main switchFunctions of the respective switch positions areas follows:ON:The engine can be started only at this position.OFF:All electrical circuits are switched off. The keycan be removed in this position.

4-1

OFF ON

4

5TG-9-12-1 4/30/05 11:15 AM Page 4-1



EBU08020

Indicator and warning lights

1. Neutral indicator light “N”2. Coolant temperature warning light “ ”

EBU06030

Neutral indicator light “N”This indicator light comes on when the transmis-sion is in neutral.

EBU13850

Coolant temperature warning light “ ”When the coolant temperature reaches a speci-fied level, this light comes on to warn that thecoolant temperature is too hot. If the light comeson during operation, stop the engine as soon asit is safe to do so and allow the engine to cooldown for about 10 minutes.The electrical circuit of the warning light can bechecked according to the following procedures.

1. Set the engine stop switch to “RUN” andturn the key to “ON”.

2. Shift the transmission into the neutral posi-tion or pull the clutch lever.

3. Push the start switch. If the warning lightdoes not come on while the start switch ispushed, have a Yamaha dealer check theelectrical circuit.

4-2

5TG-9-12-1 4/30/05 11:15 AM Page 4-2



cC8 The engine may overheat if the ATV is

overloaded. If this happens, reduce theload to specification.8 Restart after making sure that the light is

off. Continuous use while the light is onmay cause damage to the engine.

4-3

5TG-9-12-1 4/30/05 11:15 AM Page 4-3



EBU00530

Handlebar switches

1. Light switch “LIGHTS”2. Engine stop switch “ENG. STOP”3. Start switch “START”

EBU13741

Light switch “LIGHTS”Set the switch to the “LO” position to turn on thelow beam and the taillight.Set the switch to the “HI” position to turn on thehigh beam and the taillight.Set the switch to the “OFF” position to turn off allthe lights.

NOTE:The headlights and the taillight can be turned ononly when the engine is started.

EBU11580

Engine stop switch “ENG. STOP”Make sure that the engine stop switch is in the“RUN” position before starting the engine. Theengine stop switch controls ignition and can beused at all times to stop the engine, especially inan emergency. The engine will not start or runwhen the engine stop switch is turned to “OFF”.

EBU06470

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

cCSee the starting instructions on page 6-1 prior to starting the engine.

4-4

5TG-9-12-1 4/30/05 11:15 AM Page 4-4



EBU00620

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, andthe engine will return to an idle any time thehand is removed from the throttle lever.

1. Throttle lever

Before starting the engine, check the throttle tobe sure it is operating smoothly. Make sure itreturns to the idle position as soon as the leveris released.

4-5

POTENTIAL HAZARD

Malfunction of throttle.

WHAT CAN HAPPEN

The throttle could be hard to operate, mak-ing it difficult to speed up or slow downwhen you need to. This could cause anaccident.


Check the operation of the throttle leverbefore you start the engine. If it does notwork smoothly, check for the cause.Correct the problem before riding the ATV.Consult a Yamaha dealer if you canít findor solve the problem yourself.

qWARNING

5TG-9-12-1 4/30/05 11:15 AM Page 4-5



EBU11590

Speed limiterThe speed limiter keeps the throttle from fullyopening, even when the throttle lever is pushedto the maximum. Turning in the adjusting screwlimits the maximum engine power available anddecreases the maximum speed of the ATV.

1. Locknut 2. Adjusting screwa. No more than 12 mm (0.47 in)

4-6

POTENTIAL HAZARD

Improper adjustment of the speed limiterand throttle.

WHAT CAN HAPPEN

The throttle cable could be damaged.Improper throttle operation could result.You could lose control, have an accidentor be injured.


Do not turn the adjusting screw out morethan 12 mm (0.47 in). Always make surethe throttle lever free play is adjusted to 2–4 mm (0.08–0.16 in). See page 8-32.

qWARNING

5TG-9-12-1 4/30/05 11:15 AM Page 4-6



EBU00690

Clutch leverThe clutch lever is located on the left handlebarand the ignition circuit cut-off system is incorpo-rated in the clutch lever holder. Pull the clutchlever to the handlebar to disengage the clutch,and release the lever to engage the clutch. Thelever should be pulled rapidly and releasedslowly for smooth clutch operation. (Refer to“Starting a cold engine” for a description of theignition circuit cut-off system.)

1. Clutch lever

EBU13860

Brake leverThe brake lever is located on the right handle-bar. Pull it toward the handlebar to apply thefront brake.

1. Brake lever 2. Locknut3. Adjusting bolta. Distance between brake lever and handlebar grip

4-7

5TG-9-12-1 4/30/05 11:15 AM Page 4-7



The brake lever is equipped with a positionadjusting bolt. To adjust the distance betweenthe brake lever and the handlebar grip, hold thelever away from the handlebar so it does notcontact the adjusting bolt, loosen the locknut,turn the adjusting bolt, and then tighten the lock-nut.

EBU09890

Brake pedalThe brake pedal is located on the right side ofthe machine. Push down on the pedal to applythe rear brake.

1. Brake pedal

4-8

5TG-9-12-1 4/30/05 11:15 AM Page 4-8



EBU13870

Parking brake leverUse the parking brake when you have to startthe engine or park the machine, especially on aslope. To apply the parking brake, move theparking brake lever in direction a. To releasethe parking brake, move the parking brake leverin direction b.

1. Parking brake lever (Locked position)

1. Parking brake lever (Unlocked position)

4-9

5TG-9-12-1 4/30/05 11:15 AM Page 4-9



EBU00820

Shift pedalThis machine is equipped with a constant-mesh5-speed transmission. The shift pedal is locatedon the left side of the engine and is used in com-bination with the clutch when shifting.

1. Shift pedal

4-10

POTENTIAL HAZARD

Improper use of the parking brake.

WHAT CAN HAPPEN

The ATV could start moving unexpectedlyif the parking brake is not applied beforestarting the engine. This could cause lossof control or a collision.The brake disc could overheat if you ridethe ATV without releasing the parkingbrake. You could lose braking perfor-mance which could cause an accident.You could also wear out the brakes pre-maturely.


Always set the parking brake before start-ing the engine.Always be sure you have released theparking brake before you begin to ride.

qWARNING

5TG-9-12-1 4/30/05 11:15 AM Page 4-10



EBU00920

Fuel tank capRemove the fuel tank cap by turning it counter-clockwise.

1. Fuel tank cap

EBU00930

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

not flow. Always turn the lever to this posi-tion when the engine is not running.

ON:With the lever in this position, fuel flows tothe carburetor. Normal riding is done withthe lever in this position.

RES: This indicates reserve. If you run out offuel while riding, turn the lever to this posi-tion. THEN FILL THE FUEL TANK AT THEFIRST OPPORTUNITY. After refuelling,return the fuel cock lever to the “ON” posi-tion.

4-11

5TG-9-12-1 4/30/05 11:15 AM Page 4-11



EBU00950

Starter (choke) “1”Starting a cold engine requires a richer air-fuelmixture. A separate starter circuit supplies thismixture.Move in direction a to turn on the starter(choke).Move in direction b to turn off the starter(choke).Refer to “Starting a cold engine” for proper oper-ation. (See page 6-1.)

1. Starter (choke) “1”

4-12

5TG-9-12-1 4/30/05 11:15 AM Page 4-12



EBU16020

SeatTo remove the seat, insert your hand betweenthe rear of the seat and the rear fender, pull theseat lock lever, and then pull up the seat at therear.

1. Seat lock lever

To install the seat, insert the projections on thefront of the seat into the seat holders and pushdown on the seat at the rear.

NOTE:Make sure that the seat is securely fitted.

1. Projection (× 2)2. Seat holder (× 2)

4-13

5TG-9-12-1 4/30/05 11:15 AM Page 4-13



EBU13882

Front shock absorber adjustmentThe spring preload, rebound damping and com-pression damping forces of the front shockabsorbers can be adjusted to suit the rider’sweight and the riding conditions.

Adjust the spring preload as follows.1. Loosen the locknut.2. Turn the adjusting nut in direction a to

increase the spring preload and in directionb to decrease the spring preload.

1. Spring preload adjusting nut 2. Locknut3. Special wrench

4-14

POTENTIAL HAZARD

These shock absorbers contain highlypressurized nitrogen gas.

WHAT CAN HAPPEN

The shock absorbers could explode, caus-ing injury or property damage.Cylinder damage could also result in poorhandling which could cause an accident.


8 Do not tamper with or attempt to openthe cylinder assemblies.8 Do not subject the shock absorbers to

an open flame or other high heat.

qWARNING

8 Do not deform or damage the cylin-ders in any way.8 Do not dispose of a damaged or worn

out shock absorber yourself. Take theunit to a Yamaha dealer.

5TG-9-12-1 4/30/05 11:15 AM Page 4-14



NOTE:A special wrench can be obtained at a Yamahadealer to make this adjustment.

3. The length of the spring (installed) changes1.5 mm (0.06 in) per turn of the adjustingnut.

A. Spring length

4. Tighten the locknut to the specified torque.

cCAlways tighten the locknut against theadjusting nut and tighten it to the specifiedtorque.

4-15

Measurement A:Installed length:

Minimum (hard): 246.5 mm (9.7 in)Standard: 255 mm (10.0 in)Maximum (soft): 261.5 mm (10.3 in) Tightening torque:

Locknut:30 Nm (3.0 m0kgf, 22 ft0lbf)

5TG-9-12-1 4/30/05 11:15 AM Page 4-15



Adjust the rebound damping force as follows.Turn the rebound damping force adjusting screwin direction a to increase the rebound dampingforce and in direction b to decrease therebound damping force.

1. Rebound damping force adjusting screw

Adjust the compression damping force as fol-lows.Turn the compression damping force adjustingscrew in direction a to increase the compres-sion damping force and in direction b todecrease the compression damping force.

1. Compression damping force adjusting screw

4-16

From the fully turned-in positionMinimum (soft): 22 click(s) outStandard: 11 click(s) outMaximum (hard): 1 click(s) out

From the fully turned-in positionMinimum (soft): 20 click(s) outStandard: 11 click(s) outMaximum (hard): 1 click(s) out

5TG-9-12-1 4/30/05 11:15 AM Page 4-16



cCNever turn an adjusting mechanism beyondthe minimum and maximum settings.

NOTE:Although the total number of clicks of a dampingforce adjusting mechanism may not exactlymatch the above specifications due to small dif-ferences in production, the actual number ofclicks always represents the entire adjustingrange. To obtain a precise adjustment, it wouldbe advisable to check the number of clicks ofeach damping force adjusting mechanism and tomodify the specifications as necessary.

4-17

POTENTIAL HAZARD

Improper shock absorber adjustment.

WHAT CAN HAPPEN

Uneven adjustment can cause poor han-dling and loss of stability, which couldlead to an accident.


Always adjust the shock absorbers on theleft and right side to the same setting.

qWARNING

POTENTIAL HAZARD

Suspension components become hot dur-ing operation.

WHAT CAN HAPPEN

You could be burned.

qWARNING


Never touch the compression dampingforce adjuster, rebound damping forceadjuster or oil reservoir with your barehand or skin until suspension compo-nents have cooled.

5TG-9-12-1 4/30/05 11:15 AM Page 4-17



EBU13891

Rear shock absorber adjustmentThe spring preload, rebound damping and com-pression damping forces of the rear shockabsorber can be adjusted to suit the rider’sweight and the riding conditions.

Adjust the spring preload as follows.1. Remove the seat. (See page 4-13 for seat

removal and installation procedures.)2. Loosen the clamp screw at the carburetor

side, and then disconnect the air intakeduct.

1. Cramp screw

POTENTIAL HAZARD

This shock absorber contains highly pres-surized nitrogen gas.

WHAT CAN HAPPEN

The shock absorber could explode, caus-ing injury or property damage.Cylinder damage could also result in poorhandling which could cause an accident.


8 Do not tamper with or attempt to openthe cylinder assembly.8 Do not subject the shock absorber to

an open flame or other high heat.

qWARNING

8 Do not deform or damage the cylinderin any way.8 Do not dispose of a damaged or worn

out shock absorber yourself. Take theunit to a Yamaha dealer.

4-18

5TG-9-12-1 4/30/05 11:15 AM Page 4-18



3. Disconnect the hose, and then remove theair filter case by removing the bolts.

1. Hose

1. Bolt (× 4) 2. Air filter case

4-19

5TG-9-12-1 4/30/05 11:15 AM Page 4-19



4. Loosen the locknut.5. Turn the adjusting nut in direction a to

increase the spring preload and in directionb to decrease the spring preload.

1. Spring preload adjusting nut2. Locknut3. Special wrench

NOTE:A special wrench can be obtained at a Yamahadealer to make this adjustment.

6. The length of the spring (installed) changes1.5 mm (0.06 in) per turn of the adjustingnut.

A. Spring length

7. Tighten the locknut to the specified torque.

4-20

Measurement A:Installed length:

Minimum (hard): 250 mm (9.8 in)Standard: 257 mm (10.1 in)Maximum (soft): 264 mm (10.4 in)

5TG-9-12-1 4/30/05 11:15 AM Page 4-20



cCAlways tighten the locknut against theadjusting nut and tighten it to the specifiedtorque.

8. Place the air filter case in the original posi-tion, connect the air intake duct, and thentighten the clamp screw at the carburetorside.

9. Install the bolts, and then connect the hose.10. Install the seat.

Adjust the rebound damping force as follows.Turn the rebound damping force adjusting screwin direction a to increase the rebound dampingforce and in direction b to decrease therebound damping force.

NOTE:Make sure that the position indicator marks arealigned when the shock absorber is set to thestandard setting.

1. Position indicator marks

2. Rebound damping force adjusting screw4-21

Tightening torque:Locknut:

45 Nm (4.5 m0kgf, 33 ft0lbf)

Minimum (soft): Adjusting screw fullyturned outStandard: Adjusting screw 1 1/4 turns outfrom the fully turned in positionMaximum (hard): Adjusting screw fullyturned in

5TG-9-12-1 4/30/05 11:15 AM Page 4-21



Adjust the compression damping force as fol-lows.

1. Remove the seat. (See page 4-13 for seatremoval and installation procedures.)

2. Turn the compression damping force adjust-ing screw in direction a to increase thecompression damping force and in directionb to decrease the compression dampingforce.

NOTE:Make sure that the position indicator marks arealigned when the shock absorber is set to thestandard setting.

1. Compression damping force adjusting screw2. Position indicator marks

3. Install the seat.

cCNever turn an adjusting mechanism beyondthe minimum and maximum settings.

4-22

Minimum (soft): Adjusting screw fullyturned outStandard: Adjusting screw 1 3/4 turns outfrom the fully turned in positionMaximum (hard): Adjusting screw fullyturned in

5TG-9-12-1 4/30/05 11:15 AM Page 4-22



EBU01120


4-23

POTENTIAL HAZARD

Suspension components become hot dur-ing operation.

WHAT CAN HAPPEN

You could be burned.


Never touch the compression dampingforce adjuster, rebound damping forceadjuster or oil reservoir with your barehand or skin until suspension compo-nents have cooled.

qWARNING

5TG-9-12-1 4/30/05 11:15 AM Page 4-23



5-1

PRE-OPERATION CHECKSBefore using this machine, check the following points:

ITEM ROUTINE PAGE

Front brake 9 Check operation, free play, fluid level and fluid leakage. 5-3–5-49 Fill with DOT 4 brake fluid if necessary. 8-32–8-37

Rear brake 9 Check operation, free play, fluid level and fluid leakage. 5-3–5-49 Fill with DOT 4 brake fluid if necessary. 8-32–8-36, 8-38

Clutch 9 Check operation, condition and lever free play. 8-41–8-42

Parking brake 9 Check operation, condition and cable length. 8-39–8-40

Fuel 9 Check fuel level.9 Fill with fuel if necessary.

5-4–5-6

Engine oil 9 Check oil level.9 Fill with oil if necessary.

5-6, 8-9–8-14

Coolant reservoir 9 Check coolant level in reservoir.9 Fill with coolant if necessary.

5-7, 8-15–8-19

Drive chain 9 Check chain slack and condition.9 Adjust if necessary.

5-8, 8-43–8-46

Throttle 9 Check for proper throttle cable operation and free play. 5-8, 8-32

Wheels and tires 9 Check tire pressure, wear and damage. 5-9–5-10, 8-51–8-52

Fittings and fasteners 9 Check all fittings and fasteners. 5-11

Lights and switches 9 Check for proper operation. 5-11, 8-41, 8-56–8-59

5TG-9-12-1 4/30/05 11:15 AM Page 5-1



5-2

POTENTIAL HAZARD

Failure to inspect the ATV before operat-ing.Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident orequipment damage.


Always inspect your ATV each time youuse it to make sure the ATV is in safeoperating condition.Always follow the inspection and mainte-nance procedures and schedulesdescribed in the Ownerís Manual.

qWARNING

5

5TG-9-12-1 4/30/05 11:15 AM Page 5-2



EBU11660

Front and rear brakesBrake lever and brake pedal8 Check that there is no free play in the brake

lever. If there is free play, have a Yamahadealer inspect the brake system.

8 Check for correct brake pedal height. (Seepage 8-38.) If the pedal height is incorrect,have a Yamaha dealer adjust it.

8 Check the operation of the lever and pedal.They should move smoothly and there shouldbe a firm feeling when the brakes are applied.If not, have a Yamaha dealer inspect thebrake system.

Brake fluid levelCheck the brake fluid level. Add fluid if neces-sary. (See pages 8-34–8-35.)

Brake fluid leakageCheck to see if any brake fluid is leaking out ofthe pipe joints or brake fluid reservoirs. Applythe brakes firmly for one minute. If there is anyleakage, have a Yamaha dealer inspect thebrake system.

Brake operationTest the brakes at slow speed after starting outto make sure they are working properly. If thebrakes do not provide proper braking perfor-mance, inspect the brake pads for wear. (Seepage 8-32–33.)

5-3

Recommended brake fluid: DOT 4

5TG-9-12-1 4/30/05 11:15 AM Page 5-3



5-4

EBU15130

FuelMake sure there is sufficient gasoline in thetank.

cCUse only unleaded gasoline. The use of lead-ed gasoline will cause severe damage tointernal engine parts, such as the valves andpiston rings, as well as to the exhaust sys-tem.

POTENTIAL HAZARD

Riding with improperly operating brakes.

WHAT CAN HAPPEN

You could lose braking ability, whichcould lead to an accident.


Always check the brakes at the start ofevery ride. Do not ride the ATV if you findany problem with the brakes. If a problemcannot be corrected by the adjustmentprocedures provided in this manual, havea Yamaha dealer check for the cause.

qWARNING

Recommended fuel:PREMIUM UNLEADED GASOLINE ONLY

Fuel tank capacity:Total:

10.0 L (2.20 Imp gal, 2.64 US gal)Reserve:

1.9 L (0.42 Imp gal, 0.50 US gal)

5TG-9-12-1 4/30/05 11:15 AM Page 5-4



Your Yamaha engine has been designed to usepremium unleaded gasoline with a pump octanenumber ([R+M]/2) of 91 or higher, or researchoctane number of 97 or higher. If knocking orpinging occurs, use a different brand of gaso-line. Unleaded fuel will give you longer sparkplug life and reduced maintenance cost.

GasoholThere are two types of gasohol; gasohol con-taining ethanol and that containing methanol.Gasohol containing ethanol can be used ifethanol content does not exceed 10%. Gasoholcontaining methanol is not recommended byYamaha because it may cause fuel systemdamage or vehicle performance problems.

1. Fuel tank filler tube 2. Fuel level

5-5

q w

5TG-9-12-1 4/30/05 11:15 AM Page 5-5



EBU10842

Engine oilMake sure the engine oil is at the specified level.Add oil as necessary. (See page 8-9.)

cC8 In order to prevent clutch slippage (since

the engine oil also lubricates the clutch),do not mix any chemical additives. Do notuse oils with a diesel specification of “CD”or oils of a higher quality than specified. Inaddition, do not use oils labeled “ENERGYCONSERVING II” or higher.

8 Make sure that no foreign material entersthe crankcase.

5-6

Recommended engine oil type and quantity:See page 10-2.

POTENTIAL HAZARD

Improper care when refueling.

WHAT CAN HAPPEN

Fuel can spill, which can cause a fire andsevere injury.Fuel expands when it heats up. If the fueltank is overfilled, fuel could spill out dueto heat from the engine or the sun.


Do not overfill the fuel tank. Be careful notto spill fuel, especially on the engine orexhaust pipe. Wipe up any spilled fuelimmediately. Be sure the fuel tank cap isclosed securely.Do not refuel right after the engine hasbeen running and is still very hot.

qWARNING

5TG-9-12-1 4/30/05 11:15 AM Page 5-6



EBU12530

CoolantCheck the coolant level in the coolant reservoirwhen the engine is cold. (The coolant level willvary with engine temperature.) The coolant levelis satisfactory if it is between the minimum andmaximum level marks on the coolant reservoir. Ifthe coolant level is at or below the minimumlevel mark, add distilled water to bring the levelup to maximum level mark. Change the coolantevery two years. (See pages 8-15–8-19 fordetails.)

cCHard water or salt water is harmful to theengine. You may use soft water if you cannotget distilled water.

5-7

POTENTIAL HAZARD

Removing the radiator cap when theengine and radiator are still hot.

WHAT CAN HAPPEN

You could be burned by hot fluid andsteam blown out under pressure.


Wait for the engine to cool before remov-ing the radiator cap. Always use a thickrag over the cap. Allow any remainingpressure to escape before completelyremoving the cap.

qWARNING

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

0.29 L (0.26 Imp qt, 0.31 US qt)

5TG-9-12-1 4/30/05 11:15 AM Page 5-7



EBU04980

ChainCheck the general condition of the chain andcheck the chain slack before every ride.Lubricate and adjust the chain as necessary.(See pages 8-43–8-46 for details.)

EBU10830

Throttle leverCheck to see that the throttle lever operates cor-rectly. It must open smoothly and spring back tothe idle position when released. Have a Yamahadealer repair as necessary for proper operation.

EBU01570

Tires

5-8

POTENTIAL HAZARD

Operating this ATV with improper tires, orwith improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on this ATV, or oper-ation of this ATV with improper or uneventire pressure, may cause loss of control,increasing your risk of accident.


1. The tires listed below have beenapproved by Yamaha Motor Co., Ltd.for this model. Other tire combinationsare not recommended.

qWARNING

Manufacturer Size Type

Front DUNLOP AT21 × 7–10 KT341

Radial

Rear DUNLOP AT20 × 10–9 KT355A

Radial

5TG-9-12-1 4/30/05 11:15 AM Page 5-8



EBU01590

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

NOTE:The low-pressure tire gauge is included as stan-dard equipment. Make two measurements of thetire pressure and use the second reading. Dustor dirt in the gauge could cause the first readingto be incorrect.

Set pressure with tires cold.Set tire pressures to the following specifications:

5-9

2. The tires should be set to the recom-mended pressure:8 Recommended tire pressure

Front 30 kPa (0.30 kgf/cm2, 4.4 psi)Rear 35 kPa (0.35 kgf/cm2, 5.0 psi)8 Check and adjust tire pressures when

the tires are cold.8 Tire pressures must be equal on both

sides.3. Tire pressure below the minimum

specified could cause the tire to dis-lodge from the rim under severe ridingconditions.The following are minimums:

Front 27 kPa (0.27 kgf/cm2, 3.9 psi)Rear 32 kPa (0.32 kgf/cm2, 4.5 psi)

4. Use no more than the following pres-sures when seating the tire beads.

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

Higher pressures may cause the tire toburst. Inflate the tires very slowly andcarefully. Fast inflation could causethe tire to burst.

30 kPa(0.30 kgf/cm2,

4.4 psi)


3.9 psi)


4.7 psi)


5.0 psi)


4.5 psi)


5.4 psi)

Front

Rear

Recommendedpressure

Minimum Maximum

5TG-9-12-1 4/30/05 11:15 AM Page 5-9



1. Low-pressure tire gauge

EBU01600

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

a. Tire wear limit

5-10

a

5TG-9-12-1 4/30/05 11:15 AM Page 5-10



EBU11620

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.

EBU10030

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

EBU11700

SwitchesCheck the operation of all switches. Have aYamaha dealer repair as necessary for properoperation.

5-11

5TG-9-12-1 4/30/05 11:15 AM Page 5-11



EBU01610

OPERATIONwIndicates a potential hazard that could resultin serious injury or death.

EBU13911

Starting a cold engine

1. Set the parking brake.2. Turn the fuel cock to “ON”.3. Turn the main switch to “ON” and the engine

stop switch to “RUN”.4. Shift the transmission into neutral.

6-1

POTENTIAL HAZARD

Operating ATV without being familiar withall controls.

WHAT CAN HAPPEN

Loss of control, which could cause anaccident or injury.


Read the Ownerís Manual carefully. Ifthere is a control or function you do notunderstand, ask your Yamaha dealer.

qWARNING

POTENTIAL HAZARD

Freezing control cables in cold weather.

WHAT CAN HAPPEN

You could be unable to control the ATV,which could lead to an accident or colli-sion.


When riding in cold weather, always makesure all control cables work smoothlybefore you begin riding.

qWARNING

6

5TG-9-12-1 4/30/05 11:15 AM Page 6-1



NOTE:This model is equipped with an ignition circuitcut-off system.The engine can be started under the followingconditions.8 When the transmission is in neutral.

At this time the neutral indicator light shouldcome on. If the light does not come on, ask aYamaha dealer to inspect it.

8 When the clutch is disengaged with the trans-mission in any position. However, it is recom-mended to shift into neutral before starting theengine.

5. Use the starter (choke) in reference to thefigure:

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

Position 2: Cold engine start-ambient temperature at 0 ° C (30 °F)-30 ° C (90 ° F) and warming upposition.

Position 3: Cold engine start-ambient temperature above 25 ° C(80 ° F) and warm engine startposition.

1. Fully open 2. Half open3. Closed a. Starter (choke)

6. Completely close the throttle lever and startthe engine by pushing the start switch.

6-2

5TG-9-12-1 4/30/05 11:15 AM Page 6-2



NOTE:If the engine fails to start, release the startswitch, then push it again. Pause a few secondsbefore the next attempt. Each cranking shouldbe as short as possible to preserve battery ener-gy. Do not crank the engine more than 10 sec-onds on each attempt.

7. If the engine is started with the starter(choke) in position 1, the starter (choke)should be returned to position 2 to warm upthe engine. If the engine is started with thestarter (choke) in position 2 , keep thestarter (choke) in this position to warm upthe engine.

8. Continue warming up the engine until it idlessmoothly and return the starter (choke) toposition 3 before riding.

cCSee the “Engine break-in” section prior tooperating the engine for the first time.

6-3

5TG-9-12-1 4/30/05 11:15 AM Page 6-3



EBU01800

Starting a warm engineTo start a warm engine, refer to the “Starting acold engine” section. The starter (choke) shouldnot be used. The throttle should be openedslightly.

EBU01820

Warming upTo get maximum engine life, always warm upthe engine before starting off. Never acceleratehard with a cold engine! To see whether or notthe engine is warm, check if it responds to thethrottle normally with the starter (choke) turnedoff.

EBU01981

ShiftingThis model has a 5-speed forward transmission.The transmission allows you to control theamount of power you have available at a givenspeed or for starting, accelerating, climbing hills,etc. To shift into neutral, return the throttle leverto its original position, apply the clutch andrepeatedly depress the shift pedal until it stops.When it stops, it will be in first gear. Raise thepedal slightly to neutral.

1. Shift pedal N. Neutral position

6-4

5TG-9-12-1 4/30/05 11:15 AM Page 6-4



cC8 Do not coast for long periods with the

engine off, and do not tow the machine along distance. Even in neutral position, thetransmission is only properly lubricatedwhen the engine is running. Inadequatelubrication may cause damage.

8 Always use the clutch when changinggears. The engine, transmission and drivetrain are not designed to withstand theshock of forced shifting and can be dam-aged by shifting without the clutch.

6-5

5TG-9-12-1 4/30/05 11:15 AM Page 6-5



EBU14190

To start out and accelerate:1. Release the throttle lever, and then release

the parking brake.

cCAlways close the throttle while shiftinggears. Otherwise, damage to the engine anddrive train may result.

2. Pull the clutch lever to disengage the clutch.3. Shift into first gear.4. Open the throttle gradually and at the same

time, release the clutch lever slowly.5. Once the machine has attained adequate

speed, release the throttle, and at the sametime, quickly pull in the clutch lever.

6. Shift into second gear. (be careful not toshift into neutral)

7. Open the throttle part way and graduallyrelease the clutch lever.

8. Follow the same procedure when shifting tothe next higher gear.

6-6

POTENTIAL HAZARD

Opening the throttle abruptly or releasingthe clutch lever too quickly.

WHAT CAN HAPPEN

The machine could wheelie. This wouldincrease the chance of an accident,including overturn.


Open the throttle gradually.Release the clutch lever gradually.

qWARNING

5TG-9-12-1 4/30/05 11:15 AM Page 6-6



EBU02070

To decelerate:When slowing down or stopping, release thethrottle and apply the brakes smoothly andevenly. As you slow down, shift to a lower gear.Be sure that the engine has sufficiently slowedbefore engaging a lower gear. Improper use ofthe brakes or shifting can cause the tires to losetraction, reducing control and increasing thepossibility of an accident.

EBU02092

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 excessive loadon it for the first several hours of running. Duringthe first 20 hours, the various parts in the enginewear and polish themselves to the correct oper-ating clearances.During this period, prolonged full throttle opera-tion or any condition which might result in exces-sive engine heating must be avoided. However,momentary (2-3 seconds maximum) full throttleoperation under load does not harm the engine.

6-7

POTENTIAL HAZARD

Engaging a lower gear when the enginespeed is too high.

WHAT CAN HAPPEN

The wheels could stop rotating. This couldcause loss of control, an accident andinjury. It could also cause engine or drivetrain damage.


Make sure the engine has sufficientlyslowed before shifting to a lower gear.

qWARNING

5TG-9-12-1 4/30/05 11:15 AM Page 6-7



Each full throttle acceleration sequence shouldbe followed with a substantial rest period for theengine by cruising at lower r/min so the enginecan rid itself of the temporary build up of heat.If any abnormality is noticed during this period,consult a Yamaha dealer.

0-10 hours:Avoid continuous operation above half throttle.Allow a cooling off period of five to ten minutesafter every hour of operation. Vary the speed ofthe machine from time to time. Do not operate itat one set throttle position.

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

After break-in:Avoid prolonged full throttle operation. Varyspeeds occasionally.

EBU02111

ParkingWhen parking, stop the engine and shift into firstgear. Turn the fuel cock to “OFF” and apply theparking brake.

1. Locked position

6-8

5TG-9-12-1 4/30/05 11:15 AM Page 6-8



EBU14200

Parking on a slope

1. Bring the machine to a stop by applying thefront brake.

2. With the front and rear brake applied, pullthe clutch lever, shift into the neutral posi-tion, and then apply the parking brake.

3. Stop the engine by setting the engine stopswitch to “OFF”.

4. With the front and rear brakes applied, pullthe clutch lever, shift into 1st gear, and thenslowly release the clutch lever, brake leverand brake pedal.

NOTE:Make sure that the neutral indicator light goesoff.

5. Turn the key to “OFF”.

6-9

POTENTIAL HAZARD

Parking on a hill or other incline.

WHAT CAN HAPPEN

The ATV could roll out of control, increas-ing the chance of an accident.


Avoid parking on hills or other inclines. Ifyou must park on an incline, put themachine in low gear, apply the parkingbrake, and block the front and rear wheelswith rocks or other objects.Do not park the ATV at all on hills that areso steep you could not walk up them easily.

qWARNING

5TG-9-12-1 4/30/05 11:15 AM Page 6-9



EBU02210

Accessories and loading

EBU02220

AccessoriesAccessories can affect the handling and controlof your ATV. Keep the following in mind whenconsidering an accessory or operating an ATVwhich has accessories.8 Choose only accessories designed for your

ATV. Your Yamaha dealer has a variety ofgenuine Yamaha accessories. Other acces-sories may also be available on the market.However, it is not possible for Yamaha to testall non-Yamaha accessories, nor have anycontrol over the quality or suitability of them.Choose a genuine Yamaha accessory, or onethat is equivalent in design and quality.

8 Accessories should be rigidly and securelymounted. An accessory which can shift posi-tion or come off while you are riding couldaffect your ability to control the ATV.

8 Do not mount an accessory where it couldinterfere with your ability to control the ATV.Examples include (but are not limited to) aheavy or bulky object attached to the handle-bars which could make steering difficult, anaccessory that limits your ability to movearound on the seat, or one that limits yourview.

8 Use extra caution when riding an ATV withaccessories. The ATV may handle differentlythan it does without accessories.

6-10

5TG-9-12-1 4/30/05 11:15 AM Page 6-10



EBU05840

LoadingAs originally equipped, this ATV is not designedto carry cargo or tow a trailer. If you choose toadd accessories so that you can carry cargo ortow a trailer, you must use common sense andgood judgment. Keep the following points inmind:8 Never exceed the weight limits shown. An

overloaded ATV can be unstable.

8 Load cargo on the carriers as close to thecenter of the vehicle as possible. Put cargo atthe rear of the front carrier and at the front ofthe rear carrier. Center the load from side toside.

8 Tie down cargo securely to the carriers. Makesure cargo in the trailer cannot move around.A shifting load can cause an accident.

8 Make sure the load does not interfere withcontrols or your ability to see where you aregoing.

8 Ride more slowly than you would without aload. The more weight you carry, the sloweryou should go. Although conditions vary, it isgood practice not to exceed 2nd gear when-ever you are carrying heavier loads or whentowing a trailer.

8 Allow more braking distance. A heavier vehi-cle takes longer to stop.

8 Avoid making sharp turns unless at very slowspeeds.

8 Avoid hills and rough terrain. Choose terraincarefully. Added weight affects the stabilityand handling of the ATV.

6-11

MAXIMUM LOADING LIMITVehicle loading limit (total weight of cargo,rider and accessories):

100 kg (220 lb)

5TG-9-12-1 4/30/05 11:15 AM Page 6-11



EBU13552


6-12

POTENTIAL HAZARD

Overloading this ATV or carrying or tow-ing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle handlingwhich could lead to an accident.


Never exceed the stated load capacity forthis ATV.Cargo should be properly distributed andsecurely attached.Reduce speed when carrying cargo orpulling a trailer. Allow greater distance forbraking.

qWARNING

5TG-9-12-1 4/30/05 11:15 AM Page 6-12



Riding Your ATV

7

7-1

5TG-9-12-2 5/12/05 4:05 PM Page 7-1



GETTING TO KNOW YOUR ATVThis ATV is intended for recreational use byexperienced operators only.Even though you are an experienced operator ofall other all terrain vehicles or motorcycles, rid-ing the ATV requires special skills acquiredthrough practice.Take your time to fully learn techniques beforeattempting more difficult maneuvers.

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 toride, be sure you have read this Owner’s Manualcompletely and understand the operation of the

controls. Pay particular attention to the safetyinformation on pages 2-1–2-7. Please also readall caution and warning labels on your ATV.


7-3

5TG-9-12-2 5/12/05 4:05 PM Page 7-3



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 theATV’s handling and performance characteristics.

Riding your ATV requires skills acquiredthrough practice over a period of time.Take the time to learn the basic techniques wellbefore attempting more difficult maneuvers.

POTENTIAL HAZARD

Operating this ATV without proper instruc-tion.

WHAT CAN HAPPEN

The risk of an accident is greatlyincreased if the operator does not knowhow to operate the ATV properly in differ-ent situations and on different types of ter-rain.


Beginning and inexperienced operatorsshould complete the certified trainingcourse offered by Yamaha. They shouldthen regularly practice the skills learned inthe course and the operating techniquesdescribed in this Owner’s Manual.For more information about the trainingcourse, contact an authorized ATV dealeror call 1-800-887-2887.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-4



7-5

Not recommended for children under 16years of age.

POTENTIAL HAZARD

Failure to follow the age recommendationsfor this ATV.

WHAT CAN HAPPEN

Use by children of ATVs that are not rec-ommended for their age can lead to severeinjury or death of the child.


A child under 16 should never operate anATV with engine size greater than 90cc.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-5



7-6

This ATV is designed to carry operator only -passengers prohibited.

POTENTIAL HAZARD

Carrying a passenger on this ATV.

WHAT CAN HAPPEN

Greatly reduces your ability to balanceand control this ATV. Could cause an acci-dent, resulting in harm to you and/or yourpassenger.


Never carry a passenger. The long seat isto allow the operator to shift position asneeded during operation. It is not for car-rying passengers.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-6



Apparel

7-7

POTENTIAL HAZARD

Operating this ATV without wearing anapproved motorcycle helmet, eye protec-tion and protective clothing.

WHAT CAN HAPPEN

Operating without anapproved motorcyclehelmet increasesyour chances of asevere head injury ordeath in the event ofan accident.Operating withouteye protection canresult in an accidentand increases yourchances of a severeinjury in the event ofan accident.

Operating without protective clothingincreases your chances of severe injury inthe event of an accident.


Always wear an approved motorcycle hel-met that fits properly.You should also wear:

eye protection(goggles or face shield)glovesbootslong-sleeved shirt or jacketlong pants

qWARNING

Gloves

Goggles

Boots

Helmet

Protectiveclothing

5TG-9-12-2 5/12/05 4:05 PM Page 7-7



7-8

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

POTENTIAL HAZARD

Operating this ATV after consuming alco-hol or drugs.

WHAT CAN HAPPEN

Could seriously affect your judgment.Could cause you to react more slowly.Could affect your balance and perception.Could result in an accident.


Never consume alcohol or drugs before orwhile driving this ATV.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-8



7-9

Pre-operation checksAlways perform the pre-operation checks listedon page 5-1 before riding for safety and propercare of the ATV.

POTENTIAL HAZARD

Failure to inspect the ATV before operat-ing.Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident orequipment damage.


Always inspect your ATV each time youuse it to make sure the ATV is in safeoperating condition.Always follow the inspection and mainte-nance procedures and schedulesdescribed in the Owner’s Manual.

qWARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, orwith improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on this ATV, or oper-ation of this ATV with improper or uneventire pressure, may cause loss of control,increasing your risk of an accident.


Always use the size and type tires speci-fied in the Owner’s Manual for this vehicleon pages 5-8–5-9.Always maintain proper tire pressure asdescribed in the Owner’s Manual on page5-9.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-9



w

Indicates a potential hazard that could resultin serious injury or death.

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

Speed limiterFor riders inexperienced with this model, thismodel is equipped with a speed limiter in thethrottle lever housing. The speed limiter limitsthe power and top speed of the ATV. Turningthe adjusting screw in decreases the top speed,and turning it out increases the top speed. (Seepage 4-6 for details.)

1. Locknut 2. Adjusting screw

7-10

POTENTIAL HAZARD

Operating this ATV at speeds too fast foryour skills or the conditions.

WHAT CAN HAPPEN

Increases your chances of losing controlof the ATV, which can result in an acci-dent.


Always go at a speed that is proper for theterrain, visibility and operating conditions,and your experience.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-10



Loading and accessoriesAs originally equipped, this ATV is not designedto carry cargo or tow a trailer. If you choose toadd accessories so that you can carry cargo ortow a trailer, you must use common sense andgood judgment.Use extra caution when riding the ATV withadditional loads, such as accessories or cargo.The ATV’s handling may be adversely affected.Reduce your speed when adding additionalloads.

POTENTIAL HAZARD

Overloading this ATV or carrying or tow-ing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle handlingwhich could lead to an accident.


Never exceed the stated load capacity forthis ATV.Cargo should be properly distributed andsecurely attached.Reduce speed when carrying cargo orpulling a trailer. Allow greater distance forbraking.Always follow the instructions in yourOwner’s Manual for carrying cargo orpulling a trailer.

qWARNING

7-11

MAXIMUM LOADING LIMITVehicle loading limit (total weight of rider,cargo and accessories):

100 kg (220 lb)

5TG-9-12-2 5/12/05 4:05 PM Page 7-11



7-12

During operationAlways keep your feet on the footboards duringoperation. Otherwise your feet may contact therear wheels.

POTENTIAL HAZARD

Removing hands from handlebars or feetfrom footboards during operation.

WHAT CAN HAPPEN

Removing even one hand or foot canreduce your ability to control the ATV orcould cause you to lose your balance andfall off of the ATV. If you remove a footfrom a footboard, your foot or leg maycome into contact with the rear wheels,which could injure you or cause an acci-dent.


Always keep both hands on the handle-bars and both feet on the footboards ofyour ATV during operation.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-12



7-13

Avoid wheelies and jumping. You may lose con-trol of the ATV or overturn.

POTENTIAL HAZARD

Attempting wheelies, jumps, and otherstunts.

WHAT CAN HAPPEN

Increases the chance of an accident,including an overturn.


Never attempt stunts, such as wheelies orjumps. Don’t try to show off.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-13



7-14

Modifications

POTENTIAL HAZARD

Operating this ATV with improper modifi-cations.

WHAT CAN HAPPEN

Improper installation of accessories ormodification of this vehicle may causechanges in handling which in some situa-tions could lead to an accident.


Never modify this ATV through improperinstallation or use of accessories. All partsand accessories added to this vehicleshould be genuine Yamaha or equivalentcomponents designed for use on this ATVand should be installed and used accord-ing to instructions. If you have questions,consult an authorized ATV dealer.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-14



Exhaust systemThe exhaust system on the ATV is very hot dur-ing and following operation. To prevent burns,avoid touching the exhaust system. Park theATV in a place where pedestrians or childrenare not likely to touch it.

7-15

POTENTIAL HAZARD

Hot exhaust system.

WHAT CAN HAPPEN

Dry grass or brush or other combustiblematerial accumulated around the enginearea could catch fire. Someone touchingthe exhaust system during or after opera-tion could be burned.

qWARNING


Do not operate, idle, or park the ATV in drygrass or other dry ground cover.Keep the engine area free of dry grass,brush, or other combustible material.Do not touch the hot exhaust system.Do not park the ATV in a place where oth-ers might be likely to touch it.

5TG-9-12-2 5/12/05 4:05 PM Page 7-15



7-16

BE CAREFUL WHERE YOU RIDEThis ATV is designed for off-road use only.Riding on paved surfaces can cause loss of con-trol.

POTENTIAL HAZARD

Operating this ATV on paved surfaces.

WHAT CAN HAPPEN

ATVs are designed for off-road use only.Paved surfaces may seriously affect han-dling and control of the ATV, and maycause the vehicle to go out of control.


Always avoid paved surfaces, includingsidewalks, driveways, parking lots andstreets.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-16



7-17

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

POTENTIAL HAZARD

Operating this ATV on public streets,roads or highways.

WHAT CAN HAPPEN

You can collide with another vehicle.


Never operate this ATV on any publicstreet, road or highway, even a dirt orgravel one.In many states it is illegal to operate ATVson public streets, roads and highways.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-17



7-18

Know the terrain where you ride. Ride cautiouslyin unfamiliar areas. Stay alert for holes, rocks,or roots in the terrain, and other hidden haz-ards which may cause the ATV to upset.

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 to react.Could result in the ATV overturning orgoing out of control.


Go slowly and be extra careful when oper-ating on unfamiliar terrain.Always be alert to changing terrain condi-tions when operating the ATV.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-18



7-19

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 accident,including an overturn.


Do not operate on excessively rough, slip-pery or loose terrain until you havelearned and practiced the skills necessaryto control the ATV on such terrain.Always be especially cautious on thesekinds of terrain.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-19



7-20

When riding in an area where you might noteasily be seen, such as desert terrain, mount acaution flag on the ATV. DO NOT use the flagpole bracket as a trailer hitch.

Do not ride in areas posted “no trespassing”. Donot ride on private property without getting per-mission.

POTENTIAL HAZARD

Operating in areas where you might not beseen by other off-road vehicles.

qWARNING

WHAT CAN HAPPEN

You could be in a collision. You could beinjured.


Always mount a caution flag on the ATV tomake you more visible. Watch carefully forother vehicles.

5TG-9-12-2 5/12/05 4:05 PM Page 7-20



7-21

Select a large, flat area off-road to becomefamiliar with your ATV. Make sure that this areais free of obstacles and other riders. You shouldpractice control of the throttle, brakes, shiftingprocedures, and turning techniques in this areabefore trying more difficult terrain. Always avoidriding on paved surfaces: the ATV is designedfor off-road use only, and handling maneuversare more difficult to perform on pavement.

Set the parking brake and follow the instructionson page 6-1 to start the engine. Once it haswarmed up you are ready to begin riding yourATV. As you get on the ATV, be sure not toaccidentally move the shift pedal. Rememberthat the engine and exhaust pipe will be hotwhen riding and afterwards; do not allow skin orclothing to come in contact with these compo-nents.

With the engine idling, pull the clutch lever todisengage the clutch and shift into 1st gear, andthen release the parking brake. Open the throttlegradually, and at the same time, release theclutch lever slowly. Once the ATV has attainedadequate speed, release the throttle lever and atthe same time, quickly pull in the clutch leverand shift into 2nd gear. Open the throttle partway and gradually release the clutch. Use thissame procedure as you move into the highergears. Be sure to coordinate the use of the throt-tle and shift pedal properly. If the throttle isapplied too abruptly or if the throttle is notreleased during shifting, or if the shift pedal isnot released before applying the throttle, thefront wheels may lift off the ground resulting in aloss of directional control. Avoid higher speedsuntil you are thoroughly familiar with the opera-tion of your ATV.

5TG-9-12-2 5/12/05 4:05 PM Page 7-21



cCDo not shift gears without releasing thethrottle. Damage to the engine or drive trainmay occur.

When slowing down or stopping, release thethrottle and apply the brakes smoothly andevenly. As you slow down, shift to a lower gear.Be sure that the engine has sufficiently slowedbefore engaging a lower gear. Improper use ofthe brakes or shifting can cause the tires to losetraction, reducing control and increasing thepossibility of an accident.

7-22

POTENTIAL HAZARD

Engaging a lower gear when the enginespeed is too high.

WHAT CAN HAPPEN

The wheels could stop rotating. This couldcause loss of control, an accident andinjury. It could also cause engine or drivetrain damage.


Make sure the engine has sufficientlyslowed before shifting to a lower gear.

qWARNING

POTENTIAL HAZARD

Opening the throttle abruptly or releasingthe clutch lever too quickly.

WHAT CAN HAPPEN

The ATV could wheelie. This wouldincrease the chance of an accident,including overturn.


Open the throttle gradually. Release theclutch lever gradually.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-22



7-23

TURNING YOUR ATVTo achieve maximum traction while riding off-road, the two rear wheels are mounted solidlyon one axle and turn together at the samespeed. Therefore, unless the wheel on theinside of the turn is allowed to slip or lose sometraction, the ATV will resist turning. A specialturning technique must be used to allow the ATVto make turns quickly and easily. It is essentialthat this skill be learned first at low speed. As you approach a curve, slow down and begin

to turn the handlebars in the desired direction.As you do so, put your weight on the footboardto the outside of the turn (opposite your desireddirection) and lean your upper body into theturn. Use the throttle to maintain an even speedthrough the turn. This maneuver will let thewheel on the inside of the turn slip slightly,allowing the ATV to make the turn properly.

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

The ATV could go out of control, causinga collision or overturn.

qWARNING


Always follow proper procedures for turn-ing as described in this Owner’s Manual.Practice turning at low speeds beforeattempting to turn at faster speeds. Do notturn at speeds too fast for your skills orthe conditions.

5TG-9-12-2 5/12/05 4:05 PM Page 7-23



7-24

This procedure should be practiced at slowspeed many times in a large off-road area withno obstacles. If an incorrect technique is used,your ATV may continue to go straight. If the ATVdoesn’t turn, come to a stop and then practicethe procedure again. If the riding surface is slip-pery or loose, it may help to position more ofyour weight over the front wheels by moving for-ward on the seat.

Once you have learned this technique youshould be able to perform it at higher speeds orin tighter curves.

Improper riding procedures such as abrupt throt-tle changes, excessive braking, incorrect bodymovements, or too much speed for the sharp-ness of the turn may cause the ATV to tip. If theATV begins to tip over to the outside while nego-tiating a turn, lean more to the inside. It mayalso be necessary to gradually let off on thethrottle and steer to the outside of the turn toavoid tipping over.Remember: Avoid higher speeds until you arethoroughly familiar with the operation of yourATV.

5TG-9-12-2 5/12/05 4:05 PM Page 7-24



7-25

CLIMBING UPHILLUse proper riding techniques to avoid vehicleoverturns on hills. Be sure that you can maneu-ver your ATV well on flat ground before attempt-ing any incline and then practice riding first ongentle slopes. Try more difficult climbs only afteryou have developed your skill. In all cases avoidinclines with slippery or loose surfaces, or obsta-cles that might cause you to lose control.

It is important when climbing a hill to make surethat your weight is transferred forward on theATV. This can be accomplished by leaning for-ward and, on steeper inclines, standing on thefootboards and leaning forward over the handle-bars.

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.

qWARNING


Never operate the ATV on hills too steepfor the ATV or for your abilities.Practice on smaller hills before attemptinglarge hills.

5TG-9-12-2 5/12/05 4:05 PM Page 7-25



7-26

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause theATV to overturn.


Always follow proper procedures forclimbing hills as described in this Owner’sManual.Always check the terrain carefully beforeyou start up any hill.Never climb hills with excessively slipperyor loose surfaces.Shift your weight forward.Never open the throttle suddenly or makesudden gear changes.The ATV could flip over backwards.

qWARNING Never go over the top of any hill at highspeed.An obstacle, a sharp drop, or anothervehicle or person could be on the otherside of the hill.

5TG-9-12-2 5/12/05 4:05 PM Page 7-26



7-27

If you are climbing a hill and you find that youhave not properly judged your ability to make itto the top, you should turn the ATV around whileyou still have forward motion (provided you havethe room to do so) and go down the hill.

POTENTIAL HAZARD

Improperly crossing hills or turning onhills.

WHAT CAN HAPPEN



Never attempt to turn the ATV around onany hill until you have mastered the turn-ing technique as described in the Owner’sManual on level ground. Be very carefulwhen turning on any hill.Avoid crossing the side of a steep hill ifpossible.

qWARNING

When crossing the side of a hill:

Always follow proper procedures asdescribed in the Owner’s Manual.Avoid hills with excessively slippery orloose surfaces.Shift your weight to the uphill side of theATV.

5TG-9-12-2 5/12/05 4:05 PM Page 7-27



If your ATV has stalled or stopped and youbelieve you can continue up the hill, restart care-fully to make sure you do not lift the front wheelswhich could cause you to lose control. If you areunable to continue up the hill, dismount the ATVon the uphill side. Physically turn the ATVaround and then descend the hill.

If you start to roll backwards, DO NOT use therear brake to stop or try to put the ATV in gear.The ATV could easily tip over backwards.Instead, apply the front brake gradually, or dis-mount the ATV immediately on the uphill side.

7-28

POTENTIAL HAZARD

Stalling, rolling backwards or improperlydismounting while climbing a hill.

WHAT CAN HAPPEN

Could result in the ATV overturning.


Use proper gear and maintain steadyspeed when climbing a hill.

If you lose all forward speed:

Keep weight uphill.Apply the brakes.Lock the parking brake, after you arestopped.

If you begin rolling backwards:

Keep weight uphill.Never apply the rear brake while rollingbackwards.Apply the front brake.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-28



7-29

When fully stopped, apply the rearbrake as well, and then lock the parkingbrake.

Dismount on uphill side or to a side ifpointed straight uphill. Turn the ATVaround and remount, following the proce-dure described in the Owner’s Manual.

5TG-9-12-2 5/12/05 4:05 PM Page 7-29



7-30

RIDING DOWNHILLWhen riding your ATV downhill, shift your weightas far to the rear and uphill side of the ATV aspossible. Move back on the seat and sit withyour arms straight. Choose a low gear which willallow the engine compression to do most of thebraking for you. Improper braking may cause aloss of traction.Use caution while descending a hill with loose orslippery surfaces. Braking ability and tractionmay be adversely affected by these surfaces.Improper braking may also cause a loss of trac-tion.

Whenever possible, ride your ATV straightdownhill. Avoid sharp angles which could allowthe ATV to tip or roll over. Carefully choose yourpath and ride no faster than you will be able toreact to obstacles which may appear.

POTENTIAL HAZARD

Going down a hill improperly.

WHAT CAN HAPPEN



Always follow proper procedures forgoing down hills as described in thisOwner’s Manual. Note: a special techniqueis required when braking as you go downa hill.Always check the terrain carefully beforeyou 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 sharply toone side. Go straight down the hill wherepossible.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-30



7-31

5TG-9-12-2 5/12/05 4:05 PM Page 7-31



7-32

CROSSING A SLOPETraversing a sloping surface on your ATVrequires you to properly position your weight tomaintain proper balance. Be sure that you havelearned the basic riding skills on flat groundbefore attempting to cross a sloping surface.Avoid slopes with slippery surfaces or rough ter-rain that may upset your balance.

As you travel across a slope, lean your body inthe uphill direction. It may be necessary to cor-rect the steering when riding on loose surfacesby pointing the front wheels slightly uphill. Whenriding on slopes be sure not to make sharp turnseither 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 proper bal-ance, gradually steer again in the direction youwish to travel.

POTENTIAL HAZARD

Improperly crossing hills or turning onhills.

WHAT CAN HAPPEN



Never attempt to turn the ATV around onany hill until you have mastered the turn-ing technique as described in the Owner’sManual on level ground. Be very carefulwhen turning on any hill. Avoid crossingthe side of a steep hill if possible.

When crossing the side of a hill:

Always follow proper procedures asdescribed in the Owner’s Manual.Avoid hills with excessively slippery orloose surfaces.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-32



7-33

Shift your weight to the uphill side of theATV.

5TG-9-12-2 5/12/05 4:05 PM Page 7-33



7-34

CROSSING THROUGH SHALLOW WATERThe ATV can be used to cross slow moving,shallow water of up to a maximum of 35 cm (14inches) in depth. Before entering the water,choose your path carefully. Enter where there isno sharp drop off, and avoid rocks or otherobstacles which may be slippery or upset theATV. Drive slowly and carefully.

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 to anaccident.


Never operate this ATV in fast flowingwater or in water deeper than that speci-fied in your Owner’s Manual.

Remember that wet brakes may havereduced stopping ability. Test your brakesafter leaving water. If necessary, applythem several times to let friction dry outthe linings.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-34



7-35

Test your brakes after leaving the water. Do notcontinue to ride your ATV without verifying thatyou have regained proper braking ability.

cCAfter riding your ATV in water, be sure todrain the trapped water by removing thecheck hose at the bottom of the air filtercase. Wash the ATV in fresh water if it hasbeen operated in salt water or muddy condi-tions.

1. Check hose

5TG-9-12-2 5/12/05 4:05 PM Page 7-35



7-36

RIDING OVER ROUGH TERRAINRiding 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 HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Could cause loss of control or a collision.Could cause the ATV to overturn.


Before operating in a new area, check forobstacles.Never attempt to ride over large obstacles,such as large rocks or fallen trees. Whenyou go over obstacles, always followproper procedures as described in theOwner’s Manual.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-36



7-38

SLIDING AND SKIDDINGCare should be used when riding on loose orslippery surfaces since the ATV may slide. Ifunexpected and uncorrected, sliding could leadto an accident.

To reduce the tendency for the front wheels toslide in loose or slippery conditions, positioningyour weight over the front wheels will sometimeshelp.

If the rear wheels of your ATV start to slide side-ways, control can usually be regained (if there isroom to do so) by steering in the direction of theslide. Applying the brakes or accelerating is notrecommended until you have corrected theslide.

5TG-9-12-2 5/12/05 4:05 PM Page 7-38



7-39

With practice, over a period of time, skill at con-trolled sliding can be developed. The terrainshould be chosen carefully before attemptingsuch maneuvers, since both stability and controlare reduced. Bear in mind that sliding maneu-vers should always be avoided on extremelyslippery surfaces such as ice, since all controlmay be lost.

POTENTIAL HAZARD

Skidding or sliding improperly.

WHAT CAN HAPPEN

You may lose control of this ATV. Youmay also regain traction unexpectedly,which may cause the ATV to overturn.


Learn to safely control skidding or slidingby practicing at low speeds and on level,smooth terrain.On extremely slippery surfaces, such asice, go slowly and be very cautious inorder to reduce the chance of skidding orsliding out of control.

qWARNING

5TG-9-12-2 5/12/05 4:05 PM Page 7-39



7-40

WHAT TO DO IF ...This section is designed to be a reference guideonly. Be sure to read each section on ridingtechniques completely.

WHAT TO DO ...8 If your ATV doesn’t turn when you want it to:

Bring the ATV to a stop and practice the turn-ing maneuvers again. Be sure you are puttingyour weight on the footboard to the outside ofthe turn. Position your weight over the frontwheels for better control. (See pages 7-23–7-24.)

8 If your ATV begins to tip while turning:Lean more into the turn to regain balance. Ifnecessary, gradually let off the throttle and/orsteer to the outside of the turn. (See pages 7-23–7-24.)

8 If your ATV starts to slide sideways:Steer in the direction of the slide if you havethe room.Applying the brakes or accelerating is not rec-ommended until you have corrected the slide.(See pages 7-38–7-39.)

8 If your ATV can’t make it up a hill you are try-ing to climb:Turn the ATV around if you still have forwardspeed. If not, stop, dismount on the uphill sideof the ATV and physically turn the ATVaround. If the ATV starts to slip backwardsDO NOT USE THE REAR BRAKE - the ATVmay tip over on top of you. Dismount the ATVon the uphill side. (See pages 7-25–7-29.)

5TG-9-12-2 5/12/05 4:05 PM Page 7-40



7-41

8 If your ATV is traversing a sloping surface:Be sure to ride with your weight positionedtowards the uphill side of the ATV to maintainproper balance. If the ATV starts to tip, steerdown the hill (if there are no obstacles in yourway) to regain balance. If you discover thatthe ATV is going to tip over, dismount on theuphill side. (See pages 7-32–7-33.)

8 If your ATV encounters shallow water:Ride slowly and carefully through slow mov-ing water, watching for obstacles. Be sure tolet water drain from the ATV and CHECKYOUR BRAKES FOR PROPER OPERATIONwhen you come out of the water. Do not con-tinue to ride your ATV until you have regainedadequate braking ability. (See pages 7-34–7-35)


5TG-9-12-2 5/12/05 4:05 PM Page 7-41



8-1

EBU05150

PERIODIC MAINTENANCE ANDADJUSTMENT

Periodic inspection, adjustment and lubricationwill keep your machine in the safest and mostefficient condition possible. Safety is an obliga-tion of the machine owner. The most importantpoints of machine inspection, adjustment andlubrication are explained on the following pages.

EBU12210

Owner’s manual and tool kitYou are recommended to put this owner’s man-ual and low-pressure tire gauge in the vinyl bagand always carry them along with the owner’stool kit under the seat.

1. Owner’s manual 2. Owner’s tool kit3. Low-pressure tire gauge

POTENTIAL HAZARD

Servicing an engine while it is running.

WHAT CAN HAPPEN

Moving parts can catch clothing or partsof the body, causing injury.Electrical components can cause shocksor can start fires.

qWARNING


Turn off the engine when performingmaintenance unless otherwise specified.Have a Yamaha dealer perform service ifyou are not familiar with machine service.

5TG-9-12-2 5/12/05 4:05 PM Page 7-42



8-2

The service information included in this manualis intended to provide you, the owner, with thenecessary information for completing your ownpreventive maintenance and minor repairs. Thetools provided in the owner’s tool kit are suffi-cient for this purpose, except that a torquewrench is also necessary to properly tightennuts and bolts.

NOTE:If you do not have a torque wrench availableduring a service operation requiring one, takeyour machine to a Yamaha dealer to check thetorque settings and adjust them as necessary.

8

POTENTIAL HAZARD

Operating this ATV with improper modifi-cations.

WHAT CAN HAPPEN

Improper installation of accessories ormodification of this vehicle may causechanges in handling which in some situa-tions could lead to an accident.


Never modify this ATV through improperinstallation or use of accessories. All partsand accessories added to this vehicleshould be genuine Yamaha or equivalentcomponents designed for use on this ATVand should be installed and used accord-ing to instructions. If you have questions,consult an authorized Yamaha ATV dealer.

qWARNING

5TG-9-12-3 5/13/05 4:13 PM Page 8-2



8-3

INITIAL EVERYmonth 1 3 6 6 12

ITEM ROUTINEWhichever

km 320 1300 2500 2500 5000comes first(mi) (200) (800) (1600) (1600) (3200)

hours 20 80 160 160 320

Fuel line* 9 Check fuel hose for cracks or damage.2 2 2

9 Replace if necessary.

9 Check condition.Spark plug 9 Adjust gap and clean. 2 2 2 2 2

9 Replace if necessary.

Valves* 9 Check valve clearance.2 2 2 2

9 Adjust if necessary.

Carburetor* 9 Check starter (choke) operation.2 2 2 2 2

9 Adjust engine idle speed.

Crankcase breather 9 Check breather hose for cracks or damage.2 2 2system* 9 Replace if necessary.

9 Check for leakage.Exhaust system* 9 Tighten if necessary. 2 2 2

9 Replace gasket if necessary.

Spark arrester 9 Clean. 2 2 2

EBU15731

Periodic maintenance chart for the emission control systemNOTE:8 For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.8 For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind

that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

5TG-9-12-3 5/13/05 4:13 PM Page 8-3



EBU15720

General maintenance and lubrication chart

8-4



km 320 1300 2500 2500 5000comes first(mi) (200) (800) (1600) (1600) (3200)

hours 20 80 160 160 320

Air filter element 9 Clean. Every 20–40 hours 9 Replace if necessary. (more often in wet or dusty areas)

Clutch* 9 Check operation.2 2 2 29 Adjust if necessary.

9 Check free play/operation/fluid leakage/Front brake* See NOTE Page 8-6. 2 2 2 2 2

9 Correct if necessary.

9 Check operation/fluid leakage/Rear brake* See NOTE Page 8-6. 2 2 2 2 2

9 Correct if necessary.

Wheels* 9 Check balance/damage/runout.2 2 2 29 Replace if necessary.

Wheel bearings* 9 Check bearing assemblies for looseness/damage.2 2 2 29 Replace if damaged.

Rear arm pivots* 9 Lubricate every 6 months with lithium-soap-based 2 2 2grease.

Upper and lower arm9 Lubricate every 6 months with lithium-soap-based

2 2 2pivot and steering grease.shaft*

Drive chain 9 Check and adjust slack/alignment/clean/lube. 2 2 2 2 2

Fittings and fasteners* 9 Check all chassis fittings and fasteners.2 2 2 2 29 Correct if necessary.

Front and rear 9 Check operation.2 2suspension* 9 Correct if necessary.

5TG-9-12-3 5/13/05 4:13 PM Page 8-4



8-5



km 320 1300 2500 2500 5000comes first(mi) (200) (800) (1600) (1600) (3200)

hours 20 80 160 160 3209 Check operation.

Steering system* 9 Repair if damaged.2 2 2 2 29 Check toe-in.

9 Adjust if necessary.

Engine oil 9 Replace (Warm engine before draining). 2 2 2 2

Engine oil filter 9 Replace. 2 2 2element

9 Check coolant leakage.Cooling system 9 Repair if necessary. 2 2 2 2 2

9 Replace coolant every 24 months.

9 Check operation.Lights and switches*9 Adjust headlight beams. 2 2 2 2 2

5TG-9-12-3 5/13/05 4:13 PM Page 8-5



8-6


NOTE:

8Recommended brake fluid: DOT 48Brake fluid replacement:9 When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally

check the brake fluid level and add the fluid as required.9 On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two

years.9 Replace the brake hoses every four years, or if cracked or damaged.

5TG-9-12-3 5/13/05 4:13 PM Page 8-6



EBU08070

Panel removal and installation

1. Panel A

The panel illustrated needs to be removed toperform some of the maintenance described inthis chapter.Refer to this section each time the panel has tobe removed or installed.

EBU13921

Panel ATo remove


2. Remove the quick fastener screw and thebolts, and then remove the panel by pullingit out from the front of the ATV.

1. Quick fasteners 2. Bolt

8-7

5TG-9-12-3 5/13/05 4:13 PM Page 8-7



1. Bolt (× 2)

To install1. Place the panel in the original position, and

then install the quick fastener screw andthe bolts.

1. Projection (× 2) 2. Slot (× 5)


8-8

5TG-9-12-3 5/13/05 4:13 PM Page 8-8



EBU13932

Engine oil and oil filter elementThe engine oil level should be checked beforeeach ride. In addition, the oil must be changedand the oil filter element replaced at the intervalsspecified in the periodic maintenance and lubri-cation chart.

To check the engine oil level1. Place the ATV on a level surface.2. Start the engine, warm it up until the

engine oil has reached a normal tempera-ture of 40 ° C (104 ° F), let it continue toidle for ten seconds or more, and then turnthe engine off.

NOTE:To achieve the proper engine oil temperature foran accurate oil level reading, the engine musthave first completely cooled down, and thenwarmed up again for several minutes to normaloperating temperature.

3. Remove the engine oil tank filler cap, wipethe dipstick clean with a clean rag, insert itback into the filler hole (without screwing itin), and then remove it again to check theoil level.

1. Engine oil tank 2. Engine oil tank filler cap3. Dipstick 4. Maximum level mark 5. Minimum level mark6. Engine oil filler cap

NOTE:The engine oil should be between the minimumand maximum level marks.

8-9

5TG-9-12-3 5/13/05 4:13 PM Page 8-9



4. If the engine oil is below the minimum levelmark, add sufficient oil of the recommend-ed type through the engine oil tank fillerhole to raise it to the correct level.

NOTE:When adding oil, be careful not to overfill theengine oil tank; the oil level rises faster startingfrom the half-level-portion on the dipstick.

5. Insert the dipstick into the engine oil tankfiller hole, and then tighten the engine oiltank filler cap.

cCMake sure that the engine oil tank filler capis securely tightened, otherwise oil may seepout when the engine is running.

To change the engine oil (with or without oilfilter element replacement)

1. Remove the engine guard by removing thebolts.

1. Engine guard 2. Bolt (× 6)

2. Start the engine, warm it up for severalminutes, and then turn it off.

3. Place an oil pan under the engine to collectthe used oil.

8-10

5TG-9-12-3 5/13/05 4:13 PM Page 8-10



8-11

4. Remove the engine oil filler cap and thecrankcase engine oil drain bolt.

1. Crankcase engine oil drain bolt

5. Remove the engine oil tank filler cap andthe engine oil tank drain bolt.

1. Engine oil tank drain bolt

6. Check the washers for damage, andreplace if necessary.

5TG-9-12-3 5/13/05 4:13 PM Page 8-11



NOTE:Skip steps 7–10 if the oil filter element is notbeing replaced.

7. Remove the oil filter element cover byremoving the bolts, and then remove theoil filter element.

1. Oil filter element cover 2. Bolt (× 3)

8. Check the O-rings for damage, andreplace them if necessary.

1. Oil filter element 2. O-ring (× 4)

9. Install a new oil filter element and the O-rings.

NOTE:Make sure that the O-rings are properly seated.

10. Install the oil f i l ter element cover byinstalling the bolts, and then tighten themto the specified torque.

8-12

5TG-9-12-3 5/13/05 4:13 PM Page 8-12



8-13

11. Install the crankcase engine oil drain boltand the engine oil tank drain bolt, and thentighten them to the specified torques.

12. Pour the specified amount of recommend-ed engine oil through the engine oil tankfiller hole, insert the dipstick, and thentighten the engine oil tank filler cap.

13. Pour the specified amount of recommend-ed engine oil through the engine oil fillerhole, and then install and tighten theengine oil filler cap.

Recommended engine oil:See page 10-2.

Oil quantity:Without oil filter element replacement:

Quantity in oil tank:1.55 L (1.36 Imp qt, 1.64 US qt)

Quantity in crankcase:0.20 L (0.18 Imp qt, 0.21 US qt)

Total amount:1.75 L (1.54 Imp qt, 1.85 US qt)

With oil filter element replacement:Quantity in oil tank:

1.55 L (1.36 Imp qt, 1.64 US qt)Quantity in crankcase:

0.30 L (0.26 Imp qt, 0.31 US qt)Total amount:

1.85 L (1.63 Imp qt, 1.96 US qt)

Tightening torque:Oil filter element cover bolt:

10 Nm (1.0 m0kgf, 7.2 ft0lbf)

Tightening torques:Crankcase engine oil drain bolt:

20 Nm (2.0 m0kgf, 14 ft0lbf)Engine oil tank drain bolt:

19 Nm (1.9 m0kgf, 14 ft0lbf)

5TG-9-12-3 5/13/05 4:13 PM Page 8-13



cC8 In order to prevent clutch slippage (since

the engine oil also lubricates the clutch),do not mix any chemical additives. Do notuse oils with a diesel specification of “CD”or oils of a higher quality than specified. Inaddition, do not use oils labeled “ENERGYCONSERVING II” or higher.

8 Make sure that no foreign material entersthe crankcase.

14. Start the engine, and then let it idle for sev-eral minutes while checking it for oil leak-age. If oil is leaking, immediately turn theengine off and check for the cause.

15. Turn the engine off, and then check the oillevel and correct it if necessary.

16. Install the engine guard by installing thebolts, and then tighten them to the speci-fied torque.

cCBe sure to apply LOCTITE to the engineguard bolts before installing them.

8-14

Tightening torque:Engine guard bolt:

7 Nm (0.7 m0kgf, 5.1 ft0lbf)

5TG-9-12-3 5/13/05 4:13 PM Page 8-14



8-15

EBU10151

Cooling system1. Check the coolant level in the coolant

reservoir when the engine is cold as thecoolant level will vary with engine tempera-ture.

NOTE:The coolant should be between the minimumand maximum level marks.

1. Maximum level mark 2. Minimum level mark3. Coolant reservoir 4. Coolant reservoir cap

2. If the coolant is at or below the minimumlevel mark, remove the coolant reservoircap, and then add coolant or distilled waterto raise it to the specified level.

cCHard water or salt water is harmful to theengine. You may use soft water if you can’tget distilled water.

NOTE:8 If water is added, have a Yamaha dealer

check the antifreeze content of the coolant assoon as possible.

8 The radiator fan operation is completely auto-matic. It is switched on or off according to thecoolant temperature in the radiator.

If your ATV overheats, see page 8-62 for details.

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

0.29 L (0.26 Imp qt, 0.31 US qt)

5TG-9-12-3 5/13/05 4:13 PM Page 8-15



EBU13940

Changing the coolant 1. Place the ATV on a level surface.2. Remove panel A. (See page 8-7 for panel

removal and installation procedures.)3. Place a container under the engine, and

then remove the coolant drain bolt. (Use atrough or a similar object as shown.)

1. Coolant drain bolt 2. Trough

8-16

POTENTIAL HAZARD


WHAT CAN HAPPEN



Wait for the engine to cool before remov-ing the radiator cap. Always place a thickrag over the cap. Allow any remainingpressure to escape before completelyremoving the cap.

qWARNING

5TG-9-12-3 5/13/05 4:13 PM Page 8-16



4. Remove the radiator cap.

1. Radiator cap

5. Remove the coolant reservoir by removingthe bolts.

6. Remove the coolant reservoir cap, andthen turn the coolant reservoir upsidedown to empty it.

1. Coolant reservoir cap 2. Coolant reservoir3. Bolt (× 2)

7. After draining the coolant, thoroughly flushthe cooling system with clean tap water.

8. Install the coolant reservoir by installing thebolts.

8-17

5TG-9-12-3 5/13/05 4:13 PM Page 8-17



8-18

9. Replace the coolant drain bolt washer if itis damaged, install the coolant drain bolt,and then tighten it to the specified torque.

10. Pour the recommended coolant into theradiator until it is full.

11. Pour the recommended coolant into thecoolant reservoir to the maximum levelmark.

cCHard water or salt water is harmful to theengine. You may use soft water if you cannotget distilled water.

12. Install the radiator cap and the coolantreservoir cap.

Tightening torque:Coolant drain bolt:

10 Nm (1.0 m0kgf, 7.2 ft0lbf)

Recommended antifreeze:High quality ethylene glycol antifreeze

containing corrosion inhibitors for aluminumengines.Antifreeze and water mixing ratio:

1:1Total amount:

1.30 L (1.14 Imp qt, 1.37 US qt)Coolant reservoir capacity(up to the maximum level mark):

0.29 L (0.26 Imp qt, 0.31 US qt)

5TG-9-12-3 5/13/05 4:13 PM Page 8-18



13. Start the engine and let it idle for severalminutes. Stop the engine, and then checkthe coolant level in the radiator. If it is low,add more coolant until it reaches the top ofthe radiator.

14. Check the coolant level in the reservoir. If itis low, add coolant to the maximum levelmark.

15. Start the engine and then check for coolantleakage.

NOTE:If any leakage is found, have a Yamaha dealercheck the cooling system.

16. Install the panel.

EBU13951

Spark plug inspectionRemoval


2. Remove the bolts and the quick fastenerscrews.

3. Remove the fuel tank cap by turning itcounterclockwise.

1. Panel 2. Bolt (× 2)3. Quick fastener screw (× 2)4. Fuel tank cap

8-19

5TG-9-12-3 5/13/05 4:13 PM Page 8-19



8-20

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could beburned.


Always turn off the engine when removingthe fuel tank cap.Do not remove the fuel tank cap immedi-ately after the engine has been runningand is still very hot. Do not spill gasolineon the engine or exhaust pipe/muffler.Never remove the fuel tank cap whilesmoking, or in the vicinity of sparks, openflames, or other sources of ignition suchas the pilot lights of water heaters andclothes dryers.

qWARNING Before lifting the fuel tank, make sure thatthe fuel cock is in the “OFF” position andthe fuel tank cap is securely tightened.Otherwise, fuel may leak out of the carbu-retor or fuel tank.

5TG-9-12-3 5/13/05 4:13 PM Page 8-20



4. Pull the panel backward, and then removethe panel.

5. Install the fuel tank cap by turning it clock-wise.

6. Remove the bolt, lift the rear of the fueltank, and then tilt it back.

1. Bolt

7. Remove the spark plug cap.

1. Spark plug cap

8-21

5TG-9-12-3 5/13/05 4:13 PM Page 8-21



8. Use the spark plug wrench in the owner’stool kit to remove the spark plug as shown.

1. Spark plug wrench

InspectionThe spark plug is an important engine compo-nent and is easy to inspect. The condition of thespark plug can indicate the condition of theengine.The ideal color on the white insulator around thecenter electrode is a medium-to-light tan colorfor an ATV that is being ridden normally.Do not attempt to diagnose such problems your-self.Instead, take the ATV to a Yamaha dealer. Youshould periodically remove and inspect thespark plug because heat and deposits will causethe spark plug to slowly break down and erode.If electrode erosion becomes excessive, or ifcarbon and other deposits are excessive, youshould replace the spark plug with the specifiedplug.

8-22

Specified spark plug:CR8E (NGK)

5TG-9-12-3 5/13/05 4:13 PM Page 8-22



Installation1. Measure the electrode gap with a wire

thickness gauge and, if necessary, adjustthe gap to specification.

a. Spark plug gap

2. Clean the surface of the spark plug gasketand its mating surface, and then wipe offany grime from the spark plug threads.

3. Install the spark plug and tighten it to thespecified torque.

NOTE:If a torque wrench is not available when you areinstalling a spark plug, a good estimate of thecorrect torque is 1/4 to 1/2 turn past finger tight.Have the spark plug tightened to the specifiedtorque as soon as possible.

8-23

Spark plug gap:0.7–0.8 mm (0.028–0.031 in) Tightening torque:

Spark plug:12.5 Nm (1.25 m0kgf, 9.0 ft0lbf)

a

5TG-9-12-3 5/13/05 4:13 PM Page 8-23



4. Install the spark plug cap.

cCDo not use any tools to remove or install thespark plug cap, otherwise the ignition coilcoupler may be damaged. The spark plugcap may be difficult to remove because therubber seal on the end of the cap fits tightly.To remove the spark plug cap, simply twist itback and forth while pulling it out; to installit, twist it back and forth while pushing it in.

5. Place the fuel tank in the original position,and then install the bolt.

6. Remove the fuel tank cap by turning itcounterclockwise.

7. Place the panel in the original position.

1. Projection (× 4) 2. Slot (× 4)

8. Install the fuel tank cap by turning it clock-wise.

9. Install the bolts and the quick fastenerscrews.


8-24

5TG-9-12-3 5/13/05 4:13 PM Page 8-24



EBU13961

Air filter element cleaning

NOTE:There is a check hose at the bottom of the air fil-ter case. If dust or water collects in this hose,empty the hose and clean the air filter elementand air filter case.

1. Check hose


2. Remove the air f i l ter case cover byunhooking the holders.

1. Air filter case cover 2. Holder (× 3)

3. Remove the air filter element by removingthe wing bolt.

8-25

5TG-9-12-3 5/13/05 4:13 PM Page 8-25



8-26

1. Wing bolt 2. Air filter element

4. Remove the air filter element from itsframe.

1. Air filter element 2. Frame

5. Wash the air filter element gently but thor-oughly in solvent.

6. Squeeze the excess solvent out of the airfilter element and let it dry.

cCDo not twist the air filter element whensqueezing it.

7. Inspect the air filter element and replace itif damaged.

POTENTIAL HAZARD

Using low flash point solvents or gasolineto clean the air filter element.

WHAT CAN HAPPEN

Low flash point solvents or gasoline cancatch fire or explode.


Use parts cleaning solvent to clean the airfilter element.

qWARNING

5TG-9-12-3 5/13/05 4:13 PM Page 8-26



8-27

8. Apply Yamaha foam air filter oil or otherquality foam air filter oil to the air filter ele-ment.

NOTE:The air filter element should be wet but not drip-ping.

9. Pull the air filter element over its frame.10. Install the air filter element by installing the

wing bolt.11. Install the air filter case cover by hooking

the holders.12. Install the seat.

NOTE:The air filter element should be cleaned every20-40 hours. It should be cleaned and lubricatedmore often if the machine is operated in extreme-ly dusty areas. Each time air filter element main-tenance is performed, check the air inlet to theair filter case for obstructions. Check the airintake duct between the air filter case and thecarburetor and the manifold fittings for an airtightseal. Tighten all fittings securely to avoid thepossibility of unfiltered air entering the engine.

cCNever operate the engine with the air filterelement removed. This will allow unfilteredair to enter the engine, causing rapid enginewear and possible engine damage.Additionally, operation without the air filterelement will affect carburetor jetting withsubsequent poor performance and possibleengine overheating.

5TG-9-12-3 5/13/05 4:13 PM Page 8-27



8-28

EBU13633

Spark arrester cleaningSelect a well-ventilated area free of combustiblematerials and make sure the exhaust and muf-fler are cool.

1. Remove the bolt.

1. Bolt

2. Remove the tailpipe by pulling it out of themuffler.

3. Tap the tailpipe lightly, then use a wirebrush to remove any carbon deposits fromthe spark arrester portion of the tailpipeand inside of the tailpipe housing.

1. Tailpipe 2. Spark arrester

5TG-9-12-3 5/13/05 4:13 PM Page 8-28



4. Insert the tailpipe into the muffler and alignthe bolt holes.

5. Install the bolt and tighten it.6. Remove the purging bolt.

1. Purging bolt

7. Start the engine and rev it up approximate-ly twenty times while momentarily creatingexhaust system back pressure by blockingthe end of the muffler with a shop towel.

8. Stop the engine and allow the exhaust pipeto cool.

9. Install the purging bolt and tighten it.

8-29

12

5TG-9-12-3 5/13/05 4:13 PM Page 8-29



EBU02960

Carburetor adjustmentThe carburetor is a vital part of the engine andrequires very sophisticated adjustment. Mostadjusting should be left to a Yamaha dealer whohas the professional knowledge and experienceto do so. However, the idling speed may be per-formed by the owner as a part of the usual main-tenance routine.

cCThe carburetor was set at the Yamaha facto-ry after many tests. If the settings are dis-turbed by someone without sufficient techni-cal knowledge, poor engine performance anddamage may result.

8-30

POTENTIAL HAZARD

Improperly purging the exhaust systemHot exhaust system

WHAT CAN HAPPEN

Could injure the eyes.Could cause burns.Could cause carbon monoxide poisoning,possibly leading to death.Could start a fire.


When purging the exhaust system:Always let the exhaust system cool priorto touching exhaust components.Always wear eye protection, and makesure no one is behind the vehicle.Never run the engine in an enclosed area.Make sure there are no combustible mate-rials in the area.

qWARNING

5TG-9-12-3 5/13/05 4:13 PM Page 8-30



EBU13970

Idle speed adjustmentA special tester is needed to check the enginer/min on this model.Therefore, take the ATV to a Yamaha dealer tohave the idle speed adjusted.

EBU03030

Valve clearance adjustmentThe correct valve clearance changes with use,resulting in improper fuel/air supply or enginenoise. To prevent this, the valve clearance mustbe adjusted regularly. This adjustment however,should be left to a professional Yamaha servicetechnician.

8-31

Specified idle speed:1,750–1,850 r/min

5TG-9-12-3 5/13/05 4:13 PM Page 8-31



EBU03070

Throttle lever adjustment

NOTE:Adjust the engine idling speed before adjustingthe throttle lever free play.

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

lever free play is 2–4 mm (0.08–0.16 in).3. Tighten the locknut.

1. Locknut 2. Adjusting bolta. Throttle lever free play

EBU13981

Front brake pad inspectionEach brake pad is provided with a wear indicatorgroove. The indicator grooves allow checking ofbrake pad wear without disassembling thebrake. Apply the brake and inspect the wearindicator grooves. If a brake pad is worn to thepoint that the wear indicator groove is almost incontact with the disc plate, ask a Yamaha dealerto replace the brake pads as a set.

1. Wear indicator groove

8-32

1

5TG-9-12-3 5/13/05 4:13 PM Page 8-32



NOTE:The wheels need to be removed to inspect thebrake pads. (See page 8-51–8-52 for wheelremoval and installation procedures.)

EBU13990

Rear brake pad inspectionEach brake pad is provided with a wear indicatorgroove. The indicator grooves allow checking ofbrake pad wear without disassembling thebrake. Apply the brake and inspect the wearindicator grooves. If a brake pad is worn to thepoint that the wear indicator groove is almost incontact with the disc plate, ask a Yamaha dealerto replace the brake pads as a set.

1. Wear indicator groove

8-33

1

5TG-9-12-3 5/13/05 4:13 PM Page 8-33



8-34

EBU16070

Brake fluid level inspectionInsufficient brake fluid may let air enter thebrake system, possibly causing the brakes tobecome ineffective.Before riding, check that the brake fluid is abovethe minimum level mark and replenish if neces-sary. A low brake fluid level may indicate wornbrake pads and/or brake system leakage. If thebrake fluid level is low, be sure to check thebrake pads for wear and the brake system forleakage.

1. Minimum level mark

1. Minimum level mark

1Rear

Front

5TG-9-12-3 5/13/05 4:13 PM Page 8-34



8-35

NOTE:8 To access the rear brake fluid reservoir cap,

remove the seat (see page 4-13), remove therear brake fluid reservoir bracket bolt, andthen pull the rear brake fluid reservoir out tothe side as shown.

8 When installing the rear brake fluid reservoir,make sure the projection on the rear brakefluid reservoir bracket is inserted into the holein the frame.

1. Frame 2. Projection3. Rear brake fluid reservoir bracket4. Rear brake fluid reservoir bracket bolt

1. Raer brake fluid reservoir

cCDo not tilt the rear brake fluid reservoirexcessively when removing or installing therear brake fluid reservoir. Also do not twistor pull the hose of the reservoir.

Observe these precautions:8 When checking the brake fluid level, make

sure the top of the brake fluid reservoir islevel.

1

2

4

3

1

5TG-9-12-3 5/13/05 4:13 PM Page 8-35



8 Use only the designated quality brake fluid,otherwise, the rubber seals may deteriorate,causing leakage and poor brake performance.

8 Refill with the same type of brake fluid. Mixingfluids may result in a harmful chemical reac-tion and lead to poor brake performance.

8 Be careful that water does not enter the brakefluid reservoir when refilling. Water will signifi-cantly lower the boiling point of the fluid andmay result in vapor lock.

8 Brake fluid may deteriorate painted surfacesor plastic parts. Always clean up spilled fluidimmediately.

8 Have a Yamaha dealer check the cause if thebrake fluid level goes down.

EBU11860

Brake fluid replacementComplete fluid replacement should be done onlyby trained Yamaha service personnel. Have aYamaha dealer replace the following compo-nents during periodic maintenance or when theyare damaged or leaking.8 Replace the oil seals every two years.8 Replace the brake hoses every four years.

8-36

Recommended brake fluid: DOT 4

5TG-9-12-3 5/13/05 4:13 PM Page 8-36



EBU11870

Front brake lever free playThe front brake lever should have a free play ofzero mm (zero in) at the lever end. If not, have aYamaha dealer check the brake system.

a. Brake lever free play

8-37

POTENTIAL HAZARD

Operating with improperly serviced oradjusted brakes.

WHAT CAN HAPPEN



After servicing:8 Make sure the brakes operate smoothly

and that the free play is correct.8 Make sure the brakes do not drag.8 Make sure the brakes are not spongy.

All air must be bled from the brake sys-tem.

Replacement of brake componentsrequires professional knowledge. Theseprocedures should be performed by aYamaha dealer.

qWARNING

5TG-9-12-3 5/13/05 4:13 PM Page 8-37



EBU11910

Brake pedal height adjustmentThe top of the brake pedal should be positioned11.7 mm (0.46 in) below the top of the footrest.If not, have a Yamaha dealer adjust it.

a. Brake pedal position

8-38

POTENTIAL HAZARD

Operating with improperly serviced oradjusted brakes.

WHAT CAN HAPPEN



After servicing:8 Make sure the brakes operate smoothly

and that the brake pedal position is cor-rect.

8 Make sure the brakes do not drag.8 Make sure the brakes are not spongy.

All air must be bled from the brake sys-tem.

Replacement of brake componentsrequires professional knowledge. Theseprocedures should be performed by aYamaha dealer.

qWARNING

5TG-9-12-3 5/13/05 4:13 PM Page 8-38



8-39

EBU14000

Parking brake adjustmentParking brake adjustment may be required if theparking brake does not hold properly. The cablelength “A” should be adjusted to 47–51mm(1.9–2.0 in).

1. Locknut 2. Adjusting boltA. Cable length

1. Loosen the locknut and the adjusting nuton the brake cable below the fuel tank.

2. Fully loosen the locknut and the adjustingbolt at the rear brake caliper.

3. Turn the adjusting nut on the brake cablein direction a to increase the cable lengthor in direction b to decrease the cablelength.

1. Locknut 2. Adjusting bolt

NOTE:If the cable cannot be adjusted to specification,consult a Yamaha dealer.

4. Tighten the locknut on the brake cable.

1

2

A

5TG-9-12-3 5/13/05 4:13 PM Page 8-39



5. Screw in the adjusting bolt at the rearbrake caliper by hand until it feels tight,then screw it out 1/8 turn. Tighten the lock-nut to the specified torque.

cCWhen tightening the locknut, hold the adjust-ing bolt with a wrench so that the adjustingbolt does not turn together with the locknut.

8-40

POTENTIAL HAZARD

Operating with improperly adjustedbrakes.

WHAT CAN HAPPEN

The brakes could malfunction, causingreduced braking performance. This couldincrease the chance of a collision or acci-dent.


After adjusting the parking brake, blockthe rear of the machine off the ground andspin the rear wheels. Check to make surethere is no brake drag. If brake drag isnoticed, perform the adjustment again.

qWARNING

Tightening torque:Locknut:

16 Nm (1.6 m0kgf, 12 ft0lbf)

5TG-9-12-3 5/13/05 4:13 PM Page 8-40



EBU08330

Adjusting the rear brake light switchThe rear brake light switch, which is activated bythe brake pedal and brake lever, is properlyadjusted when the brake light comes on justbefore braking takes effect. If necessary, adjustthe brake light switch as follows.Turn the adjusting nut while holding the rearbrake light switch in place. To make the brakelight come on earlier, turn the adjusting nut indirection a. To make the brake light come onlater, turn the adjusting nut in direction b.

1. Rear brake light switch 2. Adjusting nut

.EBU14210

Clutch lever free play adjustmentThe clutch lever free play should be adjusted to8–13 mm (0.31–0.51 in).

1. Adjusting nut c. Cluch lever free play

1. Fully turn the adjusting nut at the clutchlever in direction a to increase the freeplay or in direction b to decrease the freeplay.

8-41

5TG-9-12-3 5/13/05 4:13 PM Page 8-41



If the specified free play cannot be obtained,proceed with the following steps.

2. Turn the adjusting nut at the clutch lever indirection a to loosen the cable.

3. Loosen the locknut at the crankcase side.4. Turn the adjusting nut at the crankcase in

direction a to increase the free play or indirection b to decrease the free play.

5. Tighten the locknut at the crankcase side.

1. Locknut 2. Adjusting nut

8-42

5TG-9-12-3 5/13/05 4:13 PM Page 8-42



EBU11440

Drive chain slack check

NOTE:Move the ATV back and forth and find the tight-est position of the drive chain. Check and/oradjust the chain slack while it is in this tightestposition.

To check the drive chain slack, all tires must betouching the ground and there should be no weighton it. Check the drive chain slack at the positionshown in the illustration Normal slack is approxi-mately 25–35 mm (0.98–1.38in). If the slackexceeds 35 mm (1.38 in), adjust it to specification.

a. Drive chain slack

8-43

5TG-9-12-3 5/13/05 4:13 PM Page 8-43



EBU15752

Adjusting the drive chain slack1. Loosen the rear axle pinch bolts.2. Insert a rod of a diameter of 8 mm and a

length of 10 cm into one of the holes in thedrive chain tensioner as shown.

1. Rear axle pinch bolt (× 4) 2. Rod3. Drive chain tensioner 4. Hole (× 3)

3. Shift the transmission into the neutral posi-tion.

4. To loosen the drive chain, push the ATVforward, and to tighten the drive chain,push the ATV backward.

cCImproper drive chain slack will overload theengine as well as other vital parts of the ATVand can lead to chain slippage or breakage.To prevent this from occurring, keep thedrive chain slack within the specified limits.

8-44

4

2 1 1

3

5TG-9-12-3 5/13/05 4:13 PM Page 8-44



5. Tighten the rear axle pinch bolts in theorder shown to the specified torque.

EBU08050

Lubricating the drive chainThe drive chain must be cleaned and lubricatedat the intervals specified in the periodic mainte-nance and lubrication chart, otherwise it willquickly wear out, especially when riding in dustyor wet areas. Service the drive chain as follows.

1. O-ring

cCThe drive chain must be lubricated afterwashing the ATV or riding in the rain.

8-45

q

Tightening torque:Rear axle pinch bolt:

21 Nm (2.1 m0kgf, 15.2 ft0lbf)

3 1 2 4

5TG-9-12-3 5/13/05 4:13 PM Page 8-45



1. Clean the drive chain with kerosene and asmall soft brush.

cCTo prevent damaging the O-rings, do notclean the drive chain with steam cleaners,high-pressure washers or inappropriate sol-vents.

2. Wipe the drive chain dry.3. Thoroughly lubricate the drive chain with a

special O-ring chain lubricant.

cCDo not use engine oil or any other lubricantsfor the drive chain, as they may contain sub-stances that could damage the O-rings.

8-46

5TG-9-12-3 5/13/05 4:13 PM Page 8-46



EBU03560

Cable inspection and lubrication Lubricate the inner cables and the cable ends. Ifthe cables do not operate smoothly, ask aYamaha dealer to replace them.

8-47

POTENTIAL HAZARD

Damaged control cables.

WHAT CAN HAPPEN

Corrosion can result when the outer cov-ering of control cables becomes damaged.Cables can also become frayed or kinked.Operation of controls could be restricted,which could cause an accident or injury.


Inspect cables frequently. Replace dam-aged cables.

qWARNING

Recommended lubricant:Yamaha chain and cable lube or SAE10W30 motor oil

5TG-9-12-3 5/13/05 4:13 PM Page 8-47



EBU14020

Brake pedal, brake lever and clutch leverlubricationLubricate the pivoting parts.

8-48

Recommended lubricant:Lithium-soap-based grease (all-purpose grease)

5TG-9-12-3 5/13/05 4:13 PM Page 8-48



EBU10180

Front upper and lower arm pivot lubricationLubricate the upper and lower arm pivots.

1. Upper grease nipple 2. Lower grease nipple (×2)

1. Upper grease nipple 2. Lower grease nipple (×2)

8-49

Recommended lubricant:Lithium-soap-based grease

Right side

Left side

5TG-9-12-3 5/13/05 4:13 PM Page 8-49



8-50

EBU10190

Rear arm pivot lubricationLubricate the rear arm pivot.

Recommended lubricant:Lithium-soap-based grease

5TG-9-12-3 5/13/05 4:13 PM Page 8-50



EBU11120

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. Nut (×4)

1. Nut (×4)

8-51

Front

Rear

5TG-9-12-3 5/13/05 4:13 PM Page 8-51



8-52

EBU07390

Wheel installationWhen installing the wheel, reverse the removalprocedure.

NOTE:The arrow mark on the tire must pointtoward the rotating direction of the wheel.

1. Arrow mark

Tighten the wheel nuts to the specified torque.

Wheel nut torque:Front: 45 Nm (4.5 m0kgf, 33 ft0lbf)Rear: 45 Nm (4.5 m0kgf, 33 ft0lbf)

5TG-9-12-3 5/13/05 4:13 PM Page 8-52



EBU03800

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.

cCDo not try to remove the sealing caps of thebattery cells. You may damage the battery.

8-53

POTENTIAL HAZARD

Failure to handle batteries or battery elec-trolyte carefully.

WHAT CAN HAPPEN

You could be poisoned. You could beseverely burned by the sulfuric acid in bat-tery electrolyte.Batteries produce explosive gases.

qWARNING


Avoid contact with skin, eyes or clothing.Always shield eyes when working nearbatteries. Keep out of reach of children.Antidote:EXTERNAL: Flush with water.INTERNAL: Drink large quantities of wateror milk. Follow with milk of magnesia,beaten egg or vegetable oil. Get promptmedical attention.EYES: Flush with water for 15 minutes andget prompt medical attention. Keep batter-ies away from sparks, flames, cigarettesor other sources of ignition. Ventilatewhen charging or using in a closed space.

5TG-9-12-3 5/13/05 4:13 PM Page 8-53



EBU03850

Battery maintenance1. When the machine is not used for a month

or longer, remove the battery and store it ina cool, dark place. Completely rechargethe battery before reinstallation.

cCA special battery charger (constantvoltage/ampere or constant voltage) isrequired for recharging a sealed-type bat-tery. Using a conventional battery chargermay shorten the battery life.

2. Always make sure the connections are cor-rect when putting the battery back in themachine.

8-54

5TG-9-12-3 5/13/05 4:13 PM Page 8-54



EBU03900

Fuse replacement1. The fuse case is located under the seat.2. If the 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, consulta Yamaha dealer.

1. Fuse 2. Spare fuse

cCTo prevent accidental short-circuiting, turnoff the main switch when checking or replac-ing a fuse.

8-55

Specified fuse: 15 A

POTENTIAL HAZARD

Using an improper fuse.

WHAT CAN HAPPEN

An improper fuse can cause damage tothe electrical system which could lead to afire.


Always use a fuse of the specified rating.Never use a material in place of the properfuse.

qWARNING

5TG-9-12-3 5/13/05 4:13 PM Page 8-55



EBU14040

Replacing a headlight bulbIf a headlight bulb burns out, replace it as fol-lows.

1. Remove the headlight assembly by remov-ing the bolts.

1. Headlight assembly 2. Bolt (×2)

2. Disconnect the headlight coupler.3. Remove the headlight bulb holder cover.

1. Headlight bulb holder cover 2. Headlight coupler

8-56

5TG-9-12-3 5/13/05 4:13 PM Page 8-56



4. Push the headlight bulb holder in and turnit counterclockwise to remove.

1. Headlight bulb holder

5. Remove the defective bulb and replace itwith a new bulb.

8-57

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 start ifthe bulb touches something flammable.


Wait for the bulb to cool before touchingor removing it.

qWARNING

5TG-9-12-3 5/13/05 4:13 PM Page 8-57



1. Do not touch the glass part of the bulb.

cCDo not touch the glass part of the headlightbulb to keep it free from oil, otherwise thetransparency of the glass, the luminosity ofthe bulb, and the bulb life will be adverselyaffected. Thoroughly clean off any dirt andfingerprints on the headlight bulb using acloth moistened with alcohol or thinner.

6. Push the headlight bulb holder in and turnit clockwise to install.

7. Install the headlight bulb holder cover.8. Connect the headlight coupler.9. Install the headlight assembly by installing

the bolts.10. Adjust the headlight beam if necessary.

8-58

5TG-9-12-3 5/13/05 4:13 PM Page 8-58



EBU14050

Headlight beam adjustment

cCIt is advisable to have a Yamaha dealer makethis adjustment.

To raise the beam, turn the adjusting bolt indirection a.To lower the beam, turn the adjusting bolt indirection b.

1. Headlight beam adjusting bolt

EBU15852

Tail/brake lightThis model is equipped with an LED type oftail/brake light.If the tail/brake light does not come on, have aYamaha dealer check it.

8-59

5TG-9-12-3 5/13/05 4:13 PM Page 8-59



EBU04120

TroubleshootingAlthough Yamaha machines receive a rigidinspection before shipment from the factory,trouble may occur during operation. Any prob-lem in the fuel, compression, or ignition systemscan cause poor starting and loss of power. Thetroubleshooting chart describes a quick, easyprocedure for making checks. If your machinerequires any repair, take it to a Yamaha dealer.The skilled technicians at a Yamaha dealershiphave the tools, experience, and know-how toproperly service your machine. Use only gen-uine Yamaha parts on your machine. Imitationparts may look like Yamaha parts, but they areoften inferior. Consequently, they have a shorterservice life and can lead to expensive repairbills.

8-60

POTENTIAL HAZARD

Checking the fuel system while smokingor near an open flame.

WHAT CAN HAPPEN

Fuel can ignite or explode, causing severeinjury or property damage.


Do not smoke when checking the fuel sys-tem. Make sure there are no open flamesor sparks in the area, including pilot lightsfrom water heaters or furnaces.

qWARNING

5TG-9-12-3 5/13/05 4:13 PM Page 8-60



8-61

EBU08061

Troubleshooting chartsStarting problems or poor engine performance

2. Compression

Use the electricstarter to see if thereis compression.

3. Ignition

Remove the spark plugand check the electrodes.

Wet Wipe clean withdry cloth.

Dry Attach spark plug capand ground to chassis.

Use the electricstarter. Spark weak.

Spark good. Ignition system normal.

No spark.

Ask a Yamaha dealer to inspect.

Adjust the spark plug gapor replace the spark plug.

There is compresson. Compression normal.

Ask a Yamaha dealer to inspect.No compression.

4. Battery

Use the electricstarter.

Engine turns overquickly. Battery is good.

Check the connections.Engine turns overslowly.

Check the fuelflow.

1. Fuel

Check if there isfuel in the fueltank.

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

Remove thefuel hose fromthe fuel cock.

Turn the fuel cocklever to “ON”.

No fuel. Fuel cock clogged.

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

Restart the engine.

No fuel. Supply fuel.

Clean the fuelcock.

5TG-9-12-3 5/13/05 4:13 PM Page 8-61



8-62

Engine overheating

NOTE:If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it ischanged to the recommended coolant as soon as possible.

POTENTIAL HAZARD


WHAT CAN HAPPEN


qWARNINGHOW TO AVOID THE HAZARD

Wait for the engine to cool before remov-ing the radiator cap.Always use a thick rag over the cap. Allowany remaining pressure to escape beforecompletely removing the cap.

Wait until the engine has cooled.

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

Level is OK.

Level is low, check the cooling system for leakage.

Noleakage.

Leakage.Ask a Yamaha dealerto inspect and repairthe cooling system.

Add coolant. (See NOTE.)

Restart the engine. If the engine overheatsagain, ask a Yamaha dealer to inspect and/orrepair the cooling system.

5TG-9-12-3 5/13/05 4:13 PM Page 8-62



EBU04170

CLEANING AND STORAGEA. CLEANINGFrequent, thorough cleaning of your machinewill not only enhance its appearance but willimprove its general performance and extend theuseful 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 filler capsare properly installed.

2. If the engine case is excessively greasy,apply degreaser with a paint brush. Do notapply degreaser to the chain, sprockets orwheel axles.

3. Rinse the dirt and degreaser off with a gar-den hose. Use only enough pressure to dothe job.

cCExcessive water pressure may cause waterseepage and deterioration of wheel bearings,brakes, transmission seals and electricaldevices. Many expensive repair bills haveresulted from improper high pressure deter-gent applications such as those available incoin-operated car washers.

4. Once the majority of the dirt has beenhosed off, wash all surfaces with warmwater and mild, detergent-type soap. Anold toothbrush or bottle brush is handy forhard-to-get-at places.

5. Rinse the machine off immediately withclean water and dry all surfaces with achamois, clean towel or soft absorbentcloth.

6. Dry the chain and lubricate it to preventrust.

9-1

5TG-9-12-3 5/13/05 4:13 PM Page 9-1



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

8. Automotive type wax may be applied to allpainted and chrome plated surfaces.Avoid combination cleaner-waxes. Manycontain abrasives which may mar the paintor protective finish.When finished, start the engine and let itidle for several minutes.

9-2

POTENTIAL HAZARD

Operation with wet brakes after washing.

WHAT CAN HAPPEN

Wet brakes may have reduced stoppingability, increasing the chance of an acci-dent.


Test the brakes after washing. Apply thebrakes several times at slow speeds to letfriction dry out the linings.

qWARNING

9

5TG-9-12-3 5/13/05 4:13 PM Page 9-2



EBU05250

B. STORAGELong term storage (60 days or more) of yourmachine will require some preventive proce-dures to guard against deterioration. After thor-oughly cleaning the machine, prepare for stor-age as follows:

1. Fill the fuel tank with fresh fuel and add thespecif ied amount of Yamaha FuelStabilizer and Conditioner or an equivalentproduct.

NOTE:Use of fuel stabilizer and conditioner eliminatesthe need to drain the fuel system. Consult aYamaha dealer if the fuel system needs to bedrained instead.

2. Remove the spark plug, pour about onetablespoon of SAE 10W30 or 20W40motor oil in the spark plug hole and rein-stall the spark plug. Ground the spark plugwire and turn the engine over several timesto coat the cylinder wall with oil.

3. Clean the drive chain thoroughly and lubri-cate it. (See page 8-45.)

4. Lubricate all control cables.5. Block up the frame to raise all wheels off

the ground.6. Tie a plastic bag over the exhaust pipe out-

let to prevent moisture from entering.7. If storing in a humid or salt-air atmosphere,

coat all exposed metal surfaces with a lightfilm of oil. Do not apply oil to any rubberparts or the seat cover.

9-3

Specified amount:1 oz of stabilizer to each gallon of fuel (or7.5 cc of stabilizer to each liter of fuel)

5TG-9-12-3 5/13/05 4:13 PM Page 9-3



8. Remove the battery and charge it. Store itin a dry place and recharge it once amonth. Do not store the battery in anexcessively warm or cold place (less than0° C (30° F) or more than 30° C (90° F)).

NOTE:Make any necessary repairs before storing themachine.

9-4

5TG-9-12-3 5/13/05 4:13 PM Page 9-4



EBU04280

SPECIFICATIONS

10-1

Model YFZ450V

Dimension:Overall length 1,840 mm ( 72.4 in)Overall width 1,170 mm ( 46.1 in)Overall height 1,090 mm ( 42.9 in)Seat height 810 mm ( 31.9 in)Wheel base 1,280 mm ( 50.4 in)Ground clearance 255 mm ( 10.04 in)Minimum turning radius: 3,500 mm (137.8 in)

Basic weight:With oil and full fuel tank 169 kg (373 lb)

Engine:Type Liquid cooled, 4-stroke, DOHCCylinder arrangement Forward-inclined single cylinderDisplacement 449.0cm3 (27.40 cu.in)Bore × Stroke 95.0 × 63.4 mm (3.74 × 2.50 in)Compression ratio 11.20 : 1Starting system Electric starterLubrication system Dry sump

5TG-9-12-3 5/13/05 4:13 PM Page 10-1



10-2

Model YFZ450V

Engine oil:Type

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

cCIn order to prevent clutch slippage (since theengine oil also lubricates the clutch), do notmix any chemical additives. Do not use oilswith a diesel specification of “CD” or oils ofa higher quality than specified. In addition,do not use oils labeled “ENERGY CONSERV-ING II” or higher.

Quantity:Without oil filter element replacement 1.75 L (1.54 lmp qt, 1.85 US qt)With oil filter element replacement 1.85 L (1.63 lmp qt, 1.96 US qt)

10°0° 30° 50° 70° 90° 110°

SAE 5W30

–20° –10° 0° 10° 20° 30° 40°

YAMALUBE 4 (20W40) or SAE20W40

YAMALUBE 4 (10W30) or SAE10W30

130°F

50°C

10

5TG-9-12-3 5/13/05 4:13 PM Page 10-2



10-3

Model YFZ450V

Cooling system:Radiator capacity (Including all routes) 1.30 L (1.14 Imp qt, 1.37 US qt)Coolant reservoir capacity (Up to the maximum level mark) 0.29 L (0.26 Imp qt, 0.31 US qt)

Air filter: Wet type element

Fuel:Type PREMIUM UNLEADED GASOLINE ONLYTank capacity 10.0 L (2.20 Imp gal, 2.64 US gal)Reserve amount 1.9 L (0.42 Imp gal, 0.50 US gal)

Carburetor:Type × quantity FCR39H × 1Manufacturer KEIHIN

Spark plug:Type/manufacturer CR8E/NGKSpark plug gap 0.7–0.8 mm (0.028–0.031 in)

Clutch :Type Wet, multiple-discOperation Left hand operation

5TG-9-12-3 5/13/05 4:13 PM Page 10-3



10-4

Model YFZ450V

Transmission:Primary reduction system Spur gearPrimary reduction ratio 62/22 (2.818)Secondary reduction system Chain driveSecondary reduction ratio 38/14 (2.714)Transmission type Constant mesh 5-speedOperation Left foot operationGear ratio1st 29/12 (2.416)2nd 27/14 (1.928)3rd 25/16 (1.562)4th 23/18 (1.277)5th 21/20 (1.050)

Chassis:Frame type Steel tube frameCaster angle 5.0°Trail 21.0 mm (0.83 in)

Tire:Type TubelessSize front AT21 × 7 - 10

rear AT20 × 10 - 9

5TG-9-12-3 5/13/05 4:13 PM Page 10-4



10-5

Model YFZ450V

Brake:Front brake type Dual disc brake

operation Right hand operationRear brake type Single disc brake

operation Right foot operation

Suspension:Front suspension Double wishboneRear suspension Swingarm (link suspension)

Shock absorber:Front shock absorber Coil spring/Gas-Oil damperRear shock absorber Coil spring/Gas-Oil damper

Wheel travel:Front wheel travel 230.0 mm (9.06 in)Rear wheel travel 270.0 mm (10.63 in)

Electrical:Ignition system D.C. C.D.I.Generator system A.C. magnetoBattery type/voltage capacity GT7B-4/12V, 6.5 Ah

Headlight type: Krypton bulb

5TG-9-12-3 5/13/05 4:13 PM Page 10-5



10-6

Model YFZ450V

Bulb voltage, wattage × quantity:Headlight 12V, 30W/30W × 2Tail/brake light LEDIndicator/warning lightNeutral 12V, 1.7W × 1Coolant temperature 12V, 1.7W × 1

Fuses:Main 15.0 A

5TG-9-12-3 5/13/05 4:13 PM Page 10-6



EBU13640

NOISE REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inopera-tive by any person other than for purposes of maintenance, repair, or replacement of any device orelement of design incorporated into any new vehicle for the purpose of noise control prior to its sale ordelivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device orelement 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.

11-1

Exhaust systemMufflerExhaust pipeSilencer

Air cleaner caseAir cleaner elementIntake duct

Intake system

5TG-9-12-3 5/13/05 4:13 PM Page 11-1



12-1

EBU15740

MAINTENANCE RECORDCopies of work orders and/or receipts for parts you purchase and install will be required to documentmaintenance done in accordance with the warranty. The chart below is printed only as a reminder toyou that the maintenance work is required. It is not acceptable proof of maintenance work.

MAINTENACEINTERVAL

1 320 (200) 20

3 1,300 (800) 80

6 2,500 (1,600) 160

12 5,000 (3,200) 320

18 7,500 (4,800) 480

24 10,000 (6,400) 640

30 12,500 (8,000) 800

36 15,000 (9,600) 960

42 17,500 (11,200) 1,120

48 20,000 (12,800) 1,280

54 22,500 (14,400) 1,440

60 25,000 (16,000) 1,600

DATE OFSERVICE

MILEAGESERVICING DEALER

NAME AND ADDRESSREMARKS

month km (mi) hours

12

11

5TG-9-12-3 5/13/05 4:13 PM Page 12-1



EBU13680

13-1

5TG-9-12-3 5/13/05 4:13 PM Page 13-1



13-2

13

5TG-9-12-3 5/13/05 4:13 PM Page 13-2



EBU13700

14-1

5TG-9-12-3 5/13/05 4:13 PM Page 14-1



14-2

14

5TG-9-12-3 5/13/05 4:13 PM Page 14-2



EEBU04360


5TG-9-12-3 5/13/05 4:13 PM Page 14-3



EBU13710

5TG-9-12-3 5/13/05 4:13 PM Page 14-5



PRINTED IN JAPAN2005.5-4.9x1 !

(E)

Improper ATV use can result in SEVERE INJURY or DEATH.

qWARNING

ALWAYS USEAN APPROVEDHELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRYPASSENGERS

NEVER USEWITH DRUGSOR ALCOHOL

NEVER operate:9 without proper training or instruction.9 at speeds too fast for your skills or the

conditions.9 on public roads - a collision can occur with

another vehicle.9 with a passenger - passengers affect

balance and steering and increase riskof losing control.

ALWAYS:9 use proper riding techniques to avoid

vehicle overturns on hills and rough ter-rain and in turns.

9 avoid paved surfaces - pavement may seriously affect handling and control.

EBU00438

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

YAMAHA MOTOR CO., LTD.PRINTED ON RECYCLED PAPER

5TG-9-12 hyoshi 5/12/05 3:16 PM Page 4



Dear New Yamaha ATV Owner:

CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV. You have purchased a qualityYamaha product that, with proper use and care, will provide hours of riding pleasure. BEFORE YOUOPERATE YOUR NEW ATV, Yamaha recommends these important points:

8 READ YOUR OWNER’S MANUAL

8 A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER

8 A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER

8 A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATERTHAN 90CC

8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA – ASK YOUR DEALER FORDETAILS OR CALL 1-800-887-2887

If you have any questions about these points, or if you purchased your ATV from an authorized Yamahadealership and were not informed of the age recommendation for your ATV by the dealership, pleasefill out the information below and mail this card to yamaha today.

De

ar Y

am

ah

a A

TV O

wn

er:

Ple

ase

Re

vie

w t

his

IMP

OR

TAN

T SA

FETY

CA

RD

be

fore

op

era

ting

yo

ur

ATV

[If

ca

rd is

no

t a

tta

ch

ed

,ca

ll 1-

800-

344-

6418

] .

RE

AD

C

AR

EF

UL

LY

Name:

Address:

Telephone:

Dealer Name & Address:

Primary I.D. [Engine Number]:

ATV Model: Purchase Date:

MO. DAY YR.

[ ]

ATV card for US 4/2/03 9:06 AM Page 1



NO POSTAGENECESSARYIF MAILED

IN THEUNITED STATES

FIRST CLASS PERMIT NO. 4 CYPRESS, CA

POSTAGE WILL BE PAID BY ADDRESSEE

YAMAHA MOTOR CORPORATION U.S.A.

P.O. BOX 6555

CYPRESS, CALIFORNIA 90630-9989

ATTN: SALES ADMINISTRATION

ATV card for US 4/2/03 9:06 AM Page 2



Documents

yfz_450