Yamaha YFM45FGPB, YFM45FGPHB, YFM450FAPB User Manual

READ THIS MANUAL CAREFULLY!
It contains important safety information.
Il comprend d’importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO
YFM45FGPB
YFM45FGPHB
YFM450FAPB
1CT-F8199-61
PRINTED IN USA
2011.06-0.7×1 CR (E,F,S)
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM45FGPB
YFM45FGPHB
YFM450FAPB
1CT-F8199-61-E0
EBU30091
Read this manual carefully before operating this vehicle. This manual should stay with this ve-
hicle if it is sold.
EC Declaration of Conformity
We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,
YFM450FWAD (YFM45FGPH) (5Y4AJ48W0B0500201–)
to which this declaration applies, conforms to the essential health and safety requirements of Directive 2006/42/EC
(If applicable)
and to the other relevant Directives of EEC
(Title and/or number and date of issue of the other Directives of EEC)
(If applicable)
To effect correct application of the essential health and safety requirements stated in the Directives of EEC, the following-standards and/or technical specifications were consulted:
(Title and/or number and date of issue of standards and/or specifications)
Manufacturer
YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA
1000 GA Highway 34 East, Newnan, Georgia 30265-1320, U.S.A.
Authorized Representative
YAMAHA MOTOR EUROPE N.V.
Koolhovenlaan 101, 1119 NC Schiphol-Rijk, The Netherlands
conforming to Directive 2006/42/EC
declare in sole responsibility, that the product
(YFM45FGP) (5Y4AJ50W0B0500201–) (YFM45FGP) (5Y4AJ47W0B0500801–)
(Make, model)
2004/108/EC
ANSI/SVIA 1-2010
Signature
General Manager RV Engineering Division Recreational Vehicle Business Unit Motorcycle Business Operations YAMAHA MOTOR CO., LTD.
Date of Issue
Shinya Shimada
2 February, 2011
EBU17170

INTRODUCTION

EBU17292
Congratulation s on y our p urcha se of the Yama ha YFM 45F GPB/Y FM 45FG PHB/ YFM45 0F APB . This ATV represents the r es u lt o f ma ny y e ars o f Y am ah a ex pe rie nc e i n th e production of fi ne s p orti n g, touring, and pacesetting 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 w ill provid e you wit h a good b asic under standing of the f eatures an d operat ion of this ATV.
This manual includes important safety information. It provides information about special tech­niques and skills n ece ssar y to ride the ATV . It a ls o i n cl u des ba s ic m ai nte nance and i n sp ec t io n pr o ce-
dures. If you h ave any ques tions rega rding the ope ration or maintenance of your AT V, please c onsult a Yamaha dealer .
AN IMPORTANT SAFETY MESSAGE:
Read this manual completely before operating your ATV. Make sure you understand all instructions.
Pay close attenti on to the wa rn ing an d no t ice lab el s on the AT V.
This ATV should not be ridden by anyone under 16 years of age.
EBU17330

IMPORTANT MANUAL INFORMATION

EBU17342
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN­JURY OR DEATH. Particularly importa nt info rma t ion is di st in gu ished in t his manua l by the fo ll ow ing no t atio ns:
This is the safety alert symbol. It is used to alert you to potential per­sonal injury hazards. Obey all safety messages that follow this sym­bol to avoid possible injury or death.
WARNING
NOTICE
TIP
A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
* Product and speci fi cat io ns are su bj ect to cha ng e wit ho ut no ti ce .
EBU17350

IMPORTANT NOTICE

EBU17372
This ATV is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway. Please check your lo cal ri di ng laws an d re gu lations before operating this ATV.
EBU17410
YFM45FGPB/YFM45FGPHB/YFM450FAPB
OWNERS MANUAL
©2011 by Yamaha Motor Co., Ltd.
1st edition, March 2011
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in U.S.A.
EBU17420

TABLE OF CONTENTS

LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................1-1
SAFETY INFORMATION ..............................2-1
DESCRIPTION ..................... .........................3-1
Left view......................................................3-1
Right view....................................................3-1
Controls and instruments ............................3-2
INSTRUMENT AND CONTROL
FUNCTIONS ..................................................4-1
Main switch ................................................4-1
Indicator lights and warning lights ..............4-2
Multi-function display ..................................4-5
Fuel gauge .................................................4-6
Handlebar switches ....................................4-6
Throttle lever ............................................4-12
Speed limiter ............................................4-12
Front brake lever ......................................4-13
Brake pedal and rear brake lever .............4-13
Drive select lever ......................................4-14
Fuel tank cap ............................................4-14
Fuel .......................................................... 4-15
Fuel cock ..................................................4-16
Starter (choke) ..........................................4-18
Seat ..........................................................4-18
Storage compartments .............................4-19
Front carrier ..............................................4-22
Rear carrier ........................... ....... .............4-22
Adjusting the front and rear shock
absorber assemblies ...............................4-22
Auxiliary DC jack .......................................4-23
PRE-OPERATION CHECKS ..........................5-1
Fuel .......................... ...................................5-3
Engine oil ....................................................5-3
Final gear oil ...... ...... ....... ...... ....... ...... ....... ..5-3
Differential gear oil ......................................5-3
Coolant .......................................................5-3
Front and rear brakes .................................5-3
Throttle lever ...............................................5-4
Tires ................................ ............................5-4
Chassis fasteners .......................................5-7
Instruments, lights and switches .................5-7
OPERATION...................................................6-1
Starting a cold engine .................................6-1
Starting a warm engine ..............................6-3
Operating the drive select lever and
driving in reverse ...................................... 6-3
Engine break-in .......................................... 6-5
Parking ................ ....................................... 6-5
Parking on a slope .....................................6-6
Accessories and loa ding ............................ 6-6
RIDING YOUR ATV ......................................7-1
GETTING TO KNOW YOUR ATV...............7-2
RIDE WITH CARE AND GOOD
JUDGMENT ..............................................7-2
BE CAREFUL WHERE YOU RIDE............. 7-9
TURNING YOUR ATV ..............................7-12
CLIMBING UPHILL ................................... 7-13
RIDING DOWNHILL.................................. 7-16
CROSSING A SLOPE...............................7-17
CROSSING THROUGH SHALLOW
WATER...................................................7-18
RIDING OVER ROUGH TERRAIN ...........7-21
SLIDING AND SKIDDING.........................7-21
WHAT TO DO IF.......................................7-23
WHAT TO DO... ........................................ 7-23
PERIODIC MAINTENANCE AND
ADJUSTMENT...............................................8-1
Owner’s manual and tool kit .......................8-2
Periodic maintenance char t for the
emission control system ................. ....... ... 8- 3
General maintenance and lubrication
chart ............................. ............................. 8-5
Removing and installing panels ........ ....... .8 -10
Checking the spark plug ...........................8-14
Engine oil and oil filter cartridge ................8-17
Final gear oil .............................................8-21
Differential gear oil ....................................8-24
Coolant .....................................................8-26
Cleaning the air filter element ...................8-30
Cleaning the spark arrester ......................8-33
V-belt cooling duct check hose .................8-35
V-belt case drain plug ...............................8-35
Adjusting the carburetor ............................8-36
Adjusting the engine idling speed .............8-36
Adjusting the throttle lever free play .........8-37
Valve clearance ........................................8-38
Adjusting the drive select lever safety
system cable ...........................................8-38
Brakes ..................... ....... ...... ....... ...... ....... .8 -38
Checking the front brake pads and rear
brake friction plates .................................8-39
Checking the brake fluid level ...................8-40
Changing the brake fluid ...........................8-41
Checking the front brake lever free play ...8-41
Adjusting the rear brake lever and
brake pedal free play, and the brake
pedal height ............................................8-41
Axle boots ................................................8-46
Brake light switches .... ...... ...... .................8-47
Checking and lubricating the cables ........8-47
Checking and lubricating the front and
rear brake levers ....................................8-48
Checking and lubricating the brake
pedal ...................................................... 8-48
Checking the wheel hub bearings ............ 8-49
Lubricating the drive shaft universal
joint ............................ ............ ....... .......... 8-49
Checking the stabilizer bushes ................8-50
Lubricating the rear knuckle pivots ...........8-50
Lubricating the steering shaft ................... 8-51
Battery ......................... .............................8-51
Replacing a fuse ......................................8-54
Replacing a headlight bulb .......................8-55
Adjusting a headlight beam ......................8-57
Replacing the tail/brake light bulb ............8-57
Removing a wheel ....................................8-59
Installing a wheel ......................................8-59
Troubleshooting ....................................... 8-61
Troubleshooting charts .............................8-62
CLEANING AND STORAGE ..........................9-1
Cleaning .......................... ............. ............. ..9-1
Storage .......................................................9-2
SPECIFICATIONS ................... ....................10-1
CONSUMER INFORMATION.......................11-1
Identification numbers ..... ...... ....... ...... ....... 11-1
EBU29680

LOCATION OF THE WARNING AND SPECIFICATION LABELS

EBU30580
Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any la bels from your ATV. If a label becomes di fficult to read or comes off, r equest a replace ­ment label from your Yamaha dealer.
For Europe
67 8 119 10
1
1-1
13
1
<
40 kg
( 88 lbs)
37S-F817R-00
2
1P0-F816P-20
4
<
80 kg
( 176 lbs)
37S-F817R-10
25.0 kPa
0.25 kgf/cm²
3.6 psi
25.0 kPa
0.25 kgf/cm²
3.6 psi
5FU-F816M-M0
5
<
5880 N
<
600 kgf
<
1322 lbf
<
147 N
<
15 kgf
<
33 lbf
37S-F817S-00
1-2
67
1P0-F816L-20
8
1P0-F816R-00
1
1-3
9
1
<
0.5 kg
( 1 lb )
37S-F816N-00
11 YFM45FGPB (panel wheel model) YFM45FGPHB
2011
YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN
YFM450FWAD
19.4 kW 281 kg
1CT-F155A-20
10
37S-F816S-00
11 YFM45FGPB (cast wheel model)
2011
YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN
1-4
YFM450FWAD
19.4 kW 284 kg
1CT-F155A-30
Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictogram s th at ap pl y to your model.
Read the Owners manual.
ALWAYS use an approved helmet and protective gear.
NEVER permit children under age 6 to operate this ATV. Operation of this ATV by children under the age of 6 increases the risk of severe injury or death. Adult supervision required for children under age 16.
NEVER permit children under age 10 to operate this ATV. Operation of this ATV by children under the age of 10 increases the risk of severe injury or death. Adult supervision required for children under age 16.
NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death. Adult supervision required for children under age 16.
NEVER operate this ATV if you are under age 16. Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
NEVER use on paved roads.
NEVER carry passengers.
1
1-5
NEVER use with drugs or alcohol.
1
Adjust the tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or
**.* kPa *.** kgf/cm²
*.* psi
death.
NEVER store fuel or flammable liquids.
**.* kPa *.** kgf/cm²
*.* psi
Turning the ATV in 4WD-LOCK (DIFF.LOCK) takes more effort. Operate at a slow speed and allow extra time and distance for maneuvers to avoid
This unit contains high-pressure nitrogen
loss of control.
gas. Mishandling can cause an explosion. Do not incinerate, puncture or open.
This pictogram shows the loading limits and/or maximum load capacity for this ATV. Follow all load limits and other loading guidelines in this manual.
Use unleaded gasoline only.
Load may include the driver, passenger, human protective gear, accessories, goods, luggage, and all other load related items. Make sure you do not exceed the load limits. Overloading can cause loss of control. Loss of control can result in severe injury or death.
Measure the tire pressure when the tires are cold.
1-6
This pictogram shows trailer Hitch Tow weight limit. (Combined weight of the trailer and all cargo in the trailer.) Overloading can cause loss of control. Loss of control can result in severe injury or death.
This pictogram shows trailer Hitch Tongue weight limit. (Weight on the trailer tongue.) Overloading can cause loss of control. Loss of control can result in severe injury or death.
1
1 2 3
****
YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN
****** *** kW *** kg
4
1
Year of construction
2
Model Name
3
Max. Power
4
Mass In Running Order
1-7
For Oceania
1
61 2 3 4 57 8 9
1-8
13
2
4
25 kPa, (3.6 psi) 25 kPa, (3.6 psi) 22 kPa, (3.2 psi) 22 kPa, (3.2 psi)
5
1
5FU-F816M-20
1-9
5880 N 1322
(600 kgf) ( 15 kgf)
37S-F151K-00
76
1
UNDER
16
1P0-F816L-00
1-10
8
1
WARNING
Fuel vapors can be a fire or explosion hazard. T o av oid injury or death, never store fuel or flammable liquids in this storage compartment.
Storage should not exceed 0.5 kg (1 lb)
37S-F151F-00
9
1-11
EBU17431

SAFETY INFORMATION

EBU17504
2
AN ATV IS NOT A TOY AND CAN BE HAZARD­OUS TO OPERATE.
An ATV handles diff erentl y fr om othe r vehicl es, in ­cluding motorcycles and cars. A collision or roll­over can occur quickly, even during routine maneuvers suc h as turning and riding on hill s or over obstacle s, if you fail to take proper precau­tions. SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this manual and all la bels carefully and fol -
low the operating procedures described.
Never operate an ATV without proper training or
instruction.
Always follow the age recommendation:
– A child under 16 years old should never oper­ate an ATV with en gin e size g rea te r than 90 c c.
Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.
Never carry a passenger on a n ATV.
Always avoid operating an ATV on any paved
surfaces, includ ing sidewalks, drive ways, park­ing lots and paved st ree ts.
Never operate an ATV on any paved street,
paved road or mo t or way .
Watch carefully for other vehicles when operat-
ing on unpaved public streets or roads. Make sure you know your countrys laws and reg ula­tions before you ride on unpav ed public s treets or roads.
Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly. You should also we ar eye prot ection (gog gles or face shield), gloves, boots, a long-sleeved shirt or a 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 riding conditions. Alway s go at a speed that is proper for the terrain , visibilit y, operat ing conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
2-1
Always inspect your ATV e ach time yo u use it t o
make sure it is in safe operating condition. Al­ways follow the inspection and maintenance procedures and schedules described in this manual.
Always keep both hand s on the ha nd le ba rs an d
both feet on the footboards of the ATV during operation.
Always go slowly and be extra careful when op-
erating on unfami liar terrain. Alwa ys be alert to changing ter rain condit ions when operating the ATV.
Never operate on ex cess ive ly r o ug h, sli pp ery or
loose terrain until you have learned and prac­ticed the skills necessary to control the ATV on such terrai n. Always be especially c autious on these kinds of terr ain .
Always follow proper procedures fo r turning as
described in this manu al. P racti ce tur ning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds.
Never operate the ATV on hills too steep for the
ATV or for your abilities. Practice on smaller hills before attempting larger hills.
Always follow proper procedures for climbing
hills as described in this manual. Check the ter­rain carefully before you start up any hill. Never climb hills with excessivel y slippery or loose sur­faces. Shift your weight forward. Never open the throttle sudd enl y. N ev er g o o ve r th e to p o f a h i ll at high speed.
Always follow proper procedures for going down
hills and for brak ing on hills as desc ribe d in thi s manual. Check the terrain careful ly 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 excessivel y slippery or loose su r­faces. Shif t your weig ht to the up hill side of the ATV. Never attemp t to turn the ATV a round on any hill until you ha ve mastered the tur ning tech­nique descri bed i n this manu al on leve l gr ound . Avoid crossing the side of a steep hill if possible.
Always use prope r pr ocedures if you stal l or ro ll
backwards when climbing a hill. To avoid stall­ing, use the proper gear range and maintain a
2
2-2
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 s i de if po in ted s tr aig ht u p-
2
hill. 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 ob stacles,
such as large rocks or fallen tre es. Always follow proper procedur es when operating ov er obsta­cles as describe d in thi s ma nu al .
Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by practicing at lo w speeds and on level, s mooth terrain. On extremely sl ipp er y surfa ces, such a s ice, go slowly and be very cautious in order to re­duce the chance of skidding or sliding out of con­trol.
Never operate an ATV in fast flowing water or in
water deeper than that recommended in this manual. Remembe r that wet brakes may have reduced stoppi ng abili ty. Test your brakes af ter leaving water. If necessary, apply them several times to let friction dry out the linings.
Always be sure there ar e no obstacles or people
behind you when yo u op er a te in re ve r s e. When it is safe to proceed in reverse, go slowly.
Always use the size and type of tires specified in
this manual .
Always maintain proper tire pressure as de-
scribed in this manual.
Never modify an ATV through improper installa-
tion or use of accessories.
Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and securely attach ed. R ed uc e spe ed an d fo ll ow in­structions in this manual for carrying cargo or pulling a trailer. All ow greate r distance fo r brak­ing.
EWB00072
WARNING
Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nau­sea, confusion, and eventually death. Carbon Monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust. Deadly levels of carbon monoxide can collect rapidly
2-3
and you can quickly be overcome and unable to save yourse lf. A lso , deadly levels of c ar b on monoxide can linger for hours or days in en­closed or poorly ventilated areas. If you experi­ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT.
Do not run engine indoors. Even if you try to
ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels.
Do not run engine in poorly ventilated or par-
tially enclosed areas such as barns, garages, or carports.
Do not run engine outdoors where engine
exhaust can be drawn into a building through openings such as windows and doors.
EWB02591
WARNING
When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.
2
2-4
EBU17680

DESCRIPTION

EBU17690

Left view

1 2 3 4 5,6 7
3
1. Radiator cap
2. Fuel cock
3. Throttle stop screw
4. Air filter case
5. Battery
6. Fuses
7. Tail/brake light
8. Engine oil filler cap
9. Oil filter cartridge
10.Coolant reservoir
11.V-belt cooling duct check hose
EBU17700

Right view

1 2 3 4 5
891011
1. Rear shock absorber assembly spring preload adjusting
ring
2. Spark arrester
3. Rear storage compartment and tool kit
4. Spark plug
5. Front shock absorber assembly spring preload adjusting
ring
6. Rear brake light switch
7. Brake pedal
8. V-belt case drain plug
678
3-1
EBU17712

Controls and instruments

954 13121110213678
1. Rear brake lever
2. Handlebar switches
3. Starter (choke)
4. Horn switch
5. Drive select lever
6. Multi-function display
7. Main switch
8. Auxiliary DC jack
9. Fuel tank cap
10.On-Command four-wheel-drive/differential gear lock switch
11.Throttle lever
12.Front brake lever
13.Front storage compartment
TIP
The ATV you have purchased may differ slightly from the figures shown in this manual.
3
3-2
EBU17733

INSTRUMENT AND CONTROL FUNCTIONS

EBU17760

Main switch

The positions of the main switch are as follows:
ON
All electrical systems are supplied with power. The
4
headlights and taillight come on when the light switch is on , and the engine can be started . The key cannot be removed.
OFF
All electrical systems are off. The key can be re­moved.
1
EPS
1. Main switch
4-1
EBU26695

Indicato r li ght s an d warn i ng li gh ts

1. On-Command differential gear lock indicator light “DIFF. LOCK
2. Low-range indicator light “L
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. P ark indicator light “P”
7. On-Command four-wheel-drive/different ial gear lock indicator “”/“”
8. Coolant temperature warning light “”
EPS
1
1. Electric Po wer Steering warning light “EPS”
EBU17990
Low-range indicator light “”
This indicator light comes on when the transmis­sion is in the low-r an ge pos it ion .
EBU17980
High-range indicator light “”
This indicator light comes on when the transmis­sion is in the high -r an ge po sit io n.
EBU17860
Neutral indicator light “”
This indicator light comes on when the transmis­sion is in the neut ra l po sit io n.
4-2
4
EBU17842
Reverse indicator light “”
This indicat or light comes on wh en the transmis­sion is in the reverse position. Furthermore, t his indicator li ght flashes when th e engine is being raced fo r 10 second s or mo r e.
TIP
If the indicato r light flashes u nder any other cir cum-
4
stances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit.
EBU17970
Park indicator light “”
This indicat or light comes on wh en the transmis­sion is in the park position.
EBU17920
Coolant temperature warning light “”
This warning light comes on when the engine over­heats. When this occurs during operation, stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes.
ECB00010
NOTICE
The engine may overheat if the ATV is over-
loaded. In this case, reduce the load to spec­ification.
Start the engine after making sure that the
warning light is out. Continuous use while the warning light is on may cause damage to the engine.
EBU27543
Electric Power Steering warning light “EPS”
This warning light comes on when the key is t urned to ON, and then goes off once the engine is start­ed. If the warning li ght rem ains on or comes on af­ter the engine is star t ed , the EP S s yst em may no t be working correctly. When this occurs, have a Yamaha dealer check th e EPS syst em . The electrical circuit of the warning light can be checked by turn ing the key to “ON”. If the warning light does not come on, have a Yamaha dealer check the electric al ci rcui t.
4-3
Loading...
+ 136 hidden pages