2005 ~ 2006 BRUIN 250 YFM250BT/ BV, BRUIN 350 2WD YFM350BAT/ BAV, BRUIN 350 4WD YFM350FAT/ FAHT/ FAV/ FAHV, BIG BEAR 400 YFM400FT/ FV, KODIAK 400 YFM400FAT/ FAHT/ FAV/ FAHV, KODIAK 450 YFM450FAT/ FAHT/ FASET/ FAV/ FAHV, and certain 2006 WOLVERINE 450 YFM450FXV FACTORY MODIFICATION CAMPAIGN Tie-Rod Ends Yamaha Technical Bulletin AT2005-007R
Yamaha Motor Corporation, U.S.A. posts this notice as a service to Yamaha customers and potential Yamaha customers. Yamaha Motor Corporation, U.S.A. has determined a defect relating to motor vehicle safety may exist in certain 2005 and 2006-model ATVs Bruin 250 (YFM250BT/ BV) Bruin 350 2WD (YFM350BAT/ BAV) Bruin 350 4WD (YFM350FAT/ FAHT / FAV/ FAVT) Big Bear 400 (YFM400FT/ FV) Kodiak 400 (YFM400FAT/ FAHT/ FAV/ FAHV) Kodiak 450 (YFM450FAT/ FAHT/ FASET/ FAV/ FAHV) certain 2006-model Wolverine 450 (YFM450FXV) Affected Models Model Name 2005 Bruin 250 2WD 2006 Bruin 250 2WD 2005 Bruin 350 Auto 2WD 2006 Bruin 350 Auto 2WD 2005 Bruin 350 Auto 4WD 2006 Bruin 350 Auto 4WD 2005 Bruin 350 Auto 4WD Hunter 2006 Bruin 350 Auto 4WD Hunter 2005 Big Bear 400 4WD 2006 Big Bear 400 4WD 2005 Kodiak 400 4WD 2006 Kodiak 400 4WD 2005 Kodiak 400 4WD/ Hunter 2006 Kodiak 400 4WD/ Hunter 2005 Kodiak 450 4WD 2006 Kodiak 450 4WD 2005 Kodiak 450 4WD Hunter 2006 Kodiak 450 4WD Hunter 2005 Kodiak 450 4WD SE 2006 Wolverine 4WD
Model Number YFM250BT YFM250BV YFM350BAT YFM350BAV YFM350FAT YFM350FAV YFM350FAHT YFM350FAHV YFM400FT YFM400FV YFM400FAT YFM400FAV YFM400FAHT YFM400FAHV YFM450FAT YFM450FAV YFM450FAHT YFM450FAHV YFM450FASET YFM450FXV
PID number range AG01Y-0116001 ~ 0120900 AG01Y-0120901 ~ 0123400 AH10Y-0012901 ~ 0016600 AH10Y-0016601 ~ 0020100 AH09Y-0019301 ~ 0023500 AH09Y-0023501 ~ 0029400 AH13Y-0002601 ~ 0003600 AH13Y-0003601 ~ 0006100 AH06Y-0055101 ~ 0057600 AH06Y-0057601 ~ 0059281 AJ15Y-0000101 ~ 0009600 AJ15Y-0009601 ~ 0011700 AJ17Y-0000101 ~ 0002100 AJ17Y-0002101 ~ 0003200 AJ14Y-0000101 ~ 0014900 AJ14Y-0014901 ~ 0018800 AJ16Y-0000101 ~ 0005300 AJ16Y-0005301 ~ 0008300 AJ18Y-0000101 ~ 0002700 AJ21Y-0000101 ~ 0001400
The reason for this recall: In affected units, the protective boots covering the steering systems tie-rod ends (universal joints) could be pinched during installation or adjustment, cutting a hole in the rubber. If this occurs, grease could escape from and contaminants such as sand or mud
could get into the assembly through the hole, causing accelerated wear. This could result in abnormal steering free play. If the ATV continues to be operated without repair, there is the potential that the ball and socket portion of the tie-rod end could wear to the point that they separate, resulting in loss of steering control, which could cause a vehicle crash with injury or death. What Yamaha has done: To correct this possible defect, Yamaha is initiating a Factory Modification Campaign in cooperation with the U.S. Consumer Product Safety Commission. Affected ATVs must have the tie-rod ends replaced with ones that have a different socket housing design to prevent the boot from being pinched. What you should do now: Do not operate your Yamaha ATV until this important modification is performed. If you are not the first owner of the ATV, and are unsure if this modification has been done, contact any authorized Yamaha Motorsports Dealer to check. Any authorized Yamaha Motorsports Dealer can perform this service. For the name and location of a dealer near you, call 1-800-88-YAMAHA or visit the Dealer Locator section of this website.

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WARNING
Improper ATV use can result in SEVERE INJURY or DEATH.
READ THIS MANUAL CAREFULLY! It contains important safety information.

BEER BEER

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL
ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns. on public roads-a collision can occur with avoid paved surfaces-pavement may another vehicle. seriously affect handling and control. with a passenger-passengers affect balance and steering and increase risk of losing control. LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558)

NEVER operate:

OWNERS MANUAL

YFM450FAT

YAMAHA MOTOR CO., LTD.
PRINTED IN USA 2004.06-4.41 CR (E)
This ATV should not be ridden by anyone under 16 years of age.

LIT-11626-18-35

1D9-F8199-10

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INTRODUCTION
Congratulations on your purchase of the Yamaha YFM450FA. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV. This manual includes important safety information. It provides information about special techniques 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 a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: G READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. G PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. G 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 INFORMATION. G THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.

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IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. A NOTE provides key information to make procedures easier or clearer.

CAUTION:

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EBU15000

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

G G G G

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 jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. 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. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. 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 these kinds of terrain. Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully 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. Never go over the top of a hill at high speed. Always follow proper procedures for going down hills and for braking on hills as described in this manual. 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 vehicle to lean sharply to one side. Go straight down the hill where possible. Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills 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 technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible. 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 a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. 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 follow proper procedures when operating over obstacles as described in this manual.

1. 2. 3. 4. 5. 6. 7. 8.

Differential gear lock indicator light DIFF. LOCK Low-range indicator light L High-range indicator light H Neutral indicator light N Reverse indicator light R Park indicator light P Differential gear lock indicator Coolant temperature warning light

DIFF. LOCK

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Low-range indicator light L This indicator light comes on when the drive select lever is in the L position.

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High-range indicator light H This indicator light comes on when the drive select lever is in the H position.

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Neutral indicator light N This indicator light comes on when the drive select lever is in the N position.

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Reverse indicator light R This indicator light comes on when the drive select lever is in the R position.

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Four-wheel-drive indicator / This indicator comes on when the 2WD/ 4WD switch is set to the 4WD position. The differential gear lock indicator DIFF.LOCK in the four-wheel-drive indicator also comes on when the LOCK-4WD switch is set to the 4WD-LOCK position.
Park indicator light P This indicator light comes on when the drive select lever is in the P (park) position.
NOTE: Due to the synchronizing mechanism in the differential gear case, the four-wheel drive indicator may not come on until the ATV starts moving.

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EBU00052
Coolant temperature warning light When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.
Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank. When the needle reaches the red line, refill the tank at the first opportunity.
The engine may overheat if the ATV is overloaded. If this happens, reduce the load to specification. After restarting, make sure that the light is out. Continuous use while the light is on may cause damage to the engine.

Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer. 010 hours: Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to time. Do not operate it at one set throttle position.

EBU00612

1020 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally.
Parking When parking, stop the engine and shift the drive select lever into the park position, then turn the fuel cock to the OFF position.

EBU06151

Parking on a slope
POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the machine transversely across the incline, apply the parking brake, and block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily.
1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the brake pedal applied, shift the drive select lever to the park position P.

EBU00221

Accessories and loading

EBU00222

Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. G Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market. However, it is not possible for Yamaha to test all non-Yamaha accessories, nor have any control over the quality or suitability of them. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality.

Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV. Do not mount an accessory where it could interfere with your ability to control the ATV. Examples include (but are not limited to) a heavy or bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view. Use extra caution when riding an ATV with accessories. The ATV may handle differently than it does without accessories.

EBU15260

Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: G Never exceed the weight limits shown. An overloaded ATV can be unstable. MAXIMUM LOADING LIMIT G Vehicle loading limit (total weight of cargo, rider and accessories, and tongue weight): 210 kg (463 lb) G Front carrier: 40 kg (88 lb) G Rear carrier: 80 kg (176 lb) G Storage compartment: 2.0 kg (4 lb) G Trailer hitch: Pulling load (total weight of trailer and cargo): 500 kgf (1,102 lbf) Tongue weight (vertical weight on trailer hitch point): 15 kgf (33 lbf)
Do not exceed the maximum tongue weight. You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Adjust the load in the trailer, if necessary, to reduce the weight on hitch. If you are carrying cargo and towing a trailer, include the tongue weight in the maximum vehicle load limit. Load cargo on the carrier as close to the center of the vehicle as possible. Put cargo at the rear of the front carrier and at the front of the rear carrier. Center the load from side to side. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. Make sure the load does not interfere with controls or your ability to see where you are going.
Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV.

POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.
Speed limiter For riders less experienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. Turning the adjusting screw in decreases top speed and turning it out increases top speed. (See pages 4-144-15 for details.)

1. Locknut 7-10

2. Adjusting screw
Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATVs handling may be adversely affected. Reduce your speed when adding additional loads. MAXIMUM LOADING LIMIT G Vehicle loading limit: 210 kg (463 lb) * Total weight of cargo, rider and accessories, and trailer hitch vertical load. G Front carrier: 40 kg (88 lb) G Rear carrier: 80 kg (176 lb) G Storage compartment: 2.0 kg (4 lb) G Trailer hitch: Pulling load: 500 kgf (1,102 lbf) Total weight of trailer and cargo. Tongue weight: 15 kgf (33 lbf) Vertical weight on trailer hitch point.
POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owners Manual for carrying cargo or pulling a trailer.
During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels.
POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation.

Avoid wheelies and jumping. You may lose control of the ATV or overturn.
POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Dont try to show off.

Modifications

POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer.
Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it.
Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it.
POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire. Someone touching the exhaust system during or after operation could be burned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material.
BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control.
POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.
Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles.
POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset.
POTENTIAL HAZARD Failure to use extra care when operating this 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 or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills. It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars.
POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills.
POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owners Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed.
An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.
POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owners Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.
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When crossing the side of a hill: Always follow proper procedures as described in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
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If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. If you start to roll backwards, DO NOT apply either brake abruptly. If you are in 2WD, apply only the front brake. When this ATV is in 4WD or 4WD-LOCK, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the downhill side. Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground. The ATV could easily tip over backwards. Apply both

U1D910.book Page 41 Thursday, May 27, 2004 11:08 AM
If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32 7-33.) If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See pages 7-347-36.)

EBU00515

PERIODIC MAINTENANCE AND ADJUSTMENT
Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.
Have a Yamaha dealer perform service if you are not familiar with machine service.

EBU14510

POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or can start fires. HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified.
Owners manual and tool kit You are recommended to put this owners manual in the vinyl bag and always carry it on the bottom of the seat as shown. Put the owners tool kit and low-pressure tire gauge under the seat.
1. Owners manual 2. Owners tool kit 3. Low-pressure tire gauge
The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the Owners tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. NOTE: If you do not have a torque wrench available during a service operation requiring one, take your machine to a Yamaha dealer to check the torque settings and adjust them as necessary.
POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer.

1. Bolt ( 2) (under fenders)
3. Remove the quick fastener screws, and then pull the panel upward to remove.
Tightening torque: Carrier bolt (top): 34 Nm (3.4 mkgf, 25 ftlbf) Carrier bolt (under fenders): 7 Nm (0.7 mkgf, 5.1 ftlbf)
1. Quick fastener screw ( 2)

2. Panel C

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Panel E To remove Remove the bolts, and then take the panel off. To install Place the panel in the original position, and then install the bolts.
Panel F To remove Pull outward on the areas shown.

1. Panel F

1. Panel E

2. Bolt ( 3)

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To install Place the panel in its original position.
Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Remove panel F. (See page 8-11 for panel removal and installation procedures.) 2. Place the ATV on a level surface. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Wait a few minutes until the oil settles. 5. Remove the engine oil filler cap and wipe off the dipstick with a clean rag.

1. Engine oil filler cap

1. Maximum level mark

2. Minimum level mark

6. Insert the dipstick in the oil filler hole (without screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the minimum and maximum level marks.
7. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 8. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. 9. Install the panel.
To change the engine oil (with or without oil filter cartridge replacement) 1. Remove panel F. (See page 8-11 for panel removal and installation procedures.) 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap. 4. Remove the engine oil drain bolt to drain the oil from the crankcase.

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

a. Spark plug gap

2. Clean the gasket surface. Wipe off any grime from the threads. 3. Install the spark plug and tighten it to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 mkgf, 12.5 ftlbf)

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Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case.

1. Fastener ( 4)

2. Air filter case cover
3. Remove the air filter element assembly.
1. Air filter case check hose
1. Remove the seat. (See pages 4-204-21 for seat removal and installation procedures.) 2. Remove the air filter case cover by unhooking the fasteners.
1. Air filter element assembly
4. Pull off the lock plate, and then remove the air filter element from its frame.
POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. 6. Squeeze the excess solvent out of the air filter element and let it dry.
1. Air filter element frame 3. Lock plate

2. Air filter element

5. Wash the element gently but thoroughly in solvent.
Do not twist the air filter element when squeezing it.
7. Inspect the air filter element and replace it if damaged.
8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element. NOTE: The air filter element should be wet but not dripping.
9. Pull the air filter element over its frame, and then install the lock plate. 10. Install the air filter element assembly. 11. Install the air filter case cover by hooking the fasteners onto the air filter case. 12. Install the seat.
NOTE: The air filter element should be cleaned every 2040 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet to the filter case for obstructions. Check the air filter case rubber joint to the carburetor and manifold fittings for an airtight seal. Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine.
Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating.

1. Upper knuckle

2. Lower knuckle
Recommended lubricant: Lithium-soap-based grease
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EBU11211
Wheel removal 1. 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.
Wheel installation 1. Install the wheel and the nuts. NOTE: G The arrow mark on the tire must point toward the rotating direction of the wheel. G Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel.

1. Nut ( 4)

1. Arrow mark
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2. Lower the ATV so that the wheel is on the ground.
Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer.

1. Tapered nut

3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5 mkgf, 40 ftlbf) Rear: 55 Nm (5.5 mkgf, 40 ftlbf)
1. Negative battery terminal 2. Positive battery terminal
U1D910.book Page 51 Thursday, May 27, 2004 11:08 AM
Do not try to remove the sealing caps of the battery cells. You may damage the battery.
POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases.
HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention. EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space.
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Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation.
A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type battery. Using a conventional battery charger may shorten the battery life. 2. Always make sure the connections are correct when putting the battery back in the machine.

Exhaust system

Muffler Exhaust pipe Silencer Air cleaner case Air cleaner element Intake duct

Intake system

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MAINTENANCE RECORD

Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

ACL-06E

MAINTENANCE INTERVAL
month km (mi) 320 (200) 1,200 (750) 2,400 (1,500) 4,800 (3,000) 7,200 (4,500) 9,600 (6,000) 12,000 (7,500) 14,400 (9,000) hours 750 900

DATE OF SERVICE

MILEAGE
SERVICING DEALER NAME AND ADDRESS

REMARKS

16,800 (10,500) 1,050 19,200 (12,000) 1,200 21,600 (13,500) 1,350 24,000 (15,000) 1,500

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YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY

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YAMAHA EXTENDED SERVICE (Y.E.S.)

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