Yamaha YFM45FGA, YFM450FAA User Manual
READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d’importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM45FGA
YFM450FAA
1CU-F8199-60
YAMAHA MOTOR CO., LTD.
PRINTED IN USA
2010.06-0.4×1 CR
(E,F,S)
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM45FGA
YFM450FAA
1CU-F8199-60-E0
EBU30100
Read this manual carefully before operating this vehicle. This manual should stay with this ve-
hicle if it is sold.
EC Declaration of Conformity
conforming to Directive 2006/42/EC
We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,
declare in sole responsibility, that the product
YFM450FWA (YFM45FG) (5Y4AJ14W0A0516867–)
(Make, model)
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
2004/108/EC
ANSI/SVIA 1-2007
Signature
General Manager
RV Engineering Division
MC Operations
YAMAHA MOTOR CO., LTD.
Date of Issue
Shinya Shimada
9 March, 2010
EBU17170
INTRODUCTION
EBU17292
Congratulations on your purchase of the Yamaha YFM45FGA/YFM450FAA. This ATV represents the result
of many years of Yamaha experience in the production of fine sporting, 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 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 the ATV. It also includes basic maintenance and inspection proce-
dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a
Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
● Read this manual completely before operating your ATV. Make sure you understand all instructions.
● Pay close attention to the warning and notice labels on the ATV.
● 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 important information is distinguished in this manual by the following notations:
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 specifications are subject to change without notice.
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 local riding laws and regulations before operating this ATV.
EBU17410
YFM45FGA/YFM450FAA
OWNER’S MANUAL
©2010 by Yamaha Motor Co., Ltd.
1st edition, May 2010
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 light ................ 4-2
Multi-function display .................................. 4-4
Fuel gauge ................................................. 4-5
Handlebar switches .................................... 4-5
Throttle lever ............................................ 4-11
Speed limiter ............................................ 4-11
Front brake lever ...................................... 4-12
Brake pedal and rear brake lever ............. 4-12
Drive select lever ...................................... 4-13
Fuel tank cap ............................................ 4-13
Fuel .......................................................... 4-14
Fuel cock ..................................................4-15
Starter (choke) ..........................................4-17
Seat ..........................................................4-17
Storage compartments .............................4-18
Front carrier ..............................................4-21
Rear carrier ...............................................4-21
Adjusting the front and rear shock
absorber assemblies ...............................4-21
Auxiliary DC jack .......................................4-22
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 loading ............................ 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 chart 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 ...........................8-40
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 ................................................ 8-45
Brake light switches ................................. 8-46
Checking and lubricating the cables ........ 8-47
Checking and lubricating the front and
rear brake levers .................................... 8-47
Checking and lubricating the brake
pedal ...................................................... 8-48
Checking the wheel hub bearings ............ 8-48
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 ................... 8-50
Battery ...................................................... 8-51
Replacing a fuse ...................................... 8-53
Replacing a headlight bulb ....................... 8-55
Adjusting a headlight beam ...................... 8-56
Replacing the tail/brake light bulb ............ 8-57
Removing a wheel .................................... 8-58
Installing a wheel ...................................... 8-59
Troubleshooting ....................................... 8-60
Troubleshooting charts ............................. 8-61
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
EBU30290
Read and understand all of the labels on your ATV. These labels contain important information for safe and
proper operation.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement 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
10
37S-F816S-00
11
2010
YAMAHA MOTOR CO., LTD.
2500 SHINGAI, IWATA, JAPAN
YFM450FWA
19.4 kW
275 kg
1CU-F155A-00
1-4
Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check
the pictograms that apply to your model.
Read the Owner’s 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.
To avoid 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
EBU17503
2
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 rollover can 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:
● Read this manual and all labels 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 engine size greater than 90 cc.
● Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she
does not have the abilities to operate it safely.
● Never carry a passenger on an ATV.
● Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, parking lots and paved streets.
● Never operate an ATV on any paved street,
paved road or motorway.
● Watch carefully for other vehicles when operat-
ing on unpaved public streets or roads. Make
sure you know your country’s laws and regulations before you ride on unpaved public streets
or roads.
● Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly. You
should also wear eye protection (goggles 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. Always go at a speed
that is proper for the terrain, visibility, operating
conditions, and your experience.
● Never attempt wheelies, jumps, or other stunts.
2-1
● 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 op-
erating 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 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 excessively slippery or loose surfaces. Shift your weight forward. Never open the
throttle suddenly. 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 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 side if pointed straight up-
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 obstacles,
such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described in this manual.
● Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
● Never operate an ATV in fast flowing water or in
water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.
● Always be sure there are no obstacles or people
behind you when you operate in reverse. 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 attached. Reduce speed and follow instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for braking.
EWB00071
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 yourself. Also, deadly levels of carbon
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 13121110213 678
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
1. Main switch
4-1
EBU17815
Indicator lights and warning light
1. On-Command differential gear lock indicator light “DIFF.
LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. Park indicator light “P”
7. On-Command four-wheel-drive/differential gear lock
indicator “”/“”
8. Coolant temperature warning light “”
EBU17990
Low-range indicator light “”
This indicator light comes on when the transmission is in the low-range position.
EBU17980
High-range indicator light “”
This indicator light comes on when the transmission is in the high-range position.
EBU17860
Neutral indicator light “”
This indicator light comes on when the transmission is in the neutral position.
EBU17842
Reverse indicator light “”
This indicator light comes on when the transmission is in the reverse position.
Furthermore, this indicator light flashes when the
engine is being raced for 10 seconds or more.
TIP
If the indicator light flashes under any other circumstances or the speedometer does not show the
speed while riding, have a Yamaha dealer check
the speed sensor circuit.
EBU17970
Park indicator light “”
This indicator light comes on when the transmission is in the park position.
4
4-2
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-
4
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.
EBU29621
On-Command four-wheel-drive indicator “”,
On-Command differential gear lock
indicator “” and indicator light “DIFF.
LOCK”
The On-Command four-wheel-drive indicator “”
comes on when the On-Command four-wheeldrive switch is set to the “4WD” position.
The On-Command differential gear lock
indicator “” and the On-Command differential
gear lock indicator light “DIFF. LOCK” come on
when the On-Command differential gear lock
switch is set to the “LOCK” position.
TIP
● Due to the synchronizing mechanism in the dif-
ferential gear case, the four-wheel-drive indicator may not come on until the ATV starts moving.
● When the On-Command differential gear lock
switch is set to “LOCK”, the indicator “” and
the indicator light “DIFF. LOCK” will flash until
the differential gear is locked. If the indicator and
the indicator light continue to flash, the differential is not locked. In this case, start moving to allow time for the differential to lock.
4-3
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