Yamaha YFM5FGPSEY 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
YFM5FGPSEY
34D-28199-60
PRINTED ON RECYCLED PAPER
IMPRIMÉ SUR PAPIER RECYCLÉ
IMPRESO EN PAPEL RECICLADO
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2008.06-0.4×1 CR
(E,F,S)
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM5FGPSEY
34D-28199-60-E0
EBU29160
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 98/37/
We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,
declare in sole responsibility, that the product
YFM550FWA (YFM5FGP) (JY4AJ41W080000001~)
to which this declaration applies, conforms to the essential health
and safety requirements of Directive 98
(
)
If applicable
and to the other relevant Directives of EEC
(
/
or number and date of issue of the other Directives of EEC
Title and
(
)
If applicable
To effect correct
stated in the Directives of EEC, the
specifications were consulted:
(
Title and
Authorized Representative
YAMAHA MOTOR EUROPE N.V.
Koolhovenlaan 101, 1119NC Schiphol-Rijk, The Netherlands
application
/
or number and date of issue of standards and/or specifications
(
Make, model
89/336/EEC or 2004/108/EC
of the
EN292 ANSI/SVIA 1-2007
EC
)
/37/
EC,
)
essential
health
following-standards and/or
and safety requirements
technical
)
Signature
General Manager
RV Engineering Division
RV Company
Date of Issue
Shinya Shimada
2 March, 2008
EBU17170
INTRODUCTION
EBU17291
Congratulations on your purchase of the Yamaha YFM5FGPSEY. 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 UNDER-
STAND ALL INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND NOTICE LABELS ON THE ATV.
● THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16
YEARS OF AGE.
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IMPORTANT MANUAL INFORMATION
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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.
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IMPORTANT NOTICE
EBU17370
Welcome to the Yamaha world of motor sports!
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.
EBU17390
YFM5FGPSEY
OWNER’S MANUAL
©2008 by Yamaha Motor Co., Ltd.
1st edition, June 2008
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
EBU17420
TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 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
Multifunction display ................................... 4-5
Handlebar switches .................................... 4-7
Throttle lever ............................................ 4-12
Speed limiter ............................................ 4-13
Front brake lever ...................................... 4-14
Brake pedal and rear brake lever ............. 4-14
Drive select lever ...................................... 4-15
Fuel tank cap ............................................ 4-15
Fuel .......................................................... 4-16
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
Pre-operation check list ..............................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 .................................5-4
Throttle lever ...............................................5-4
Tires ............................................................5-5
Measuring the tire pressure ........................5-6
Tire wear limit .............................................5-7
Chassis fasteners .......................................5-7
Instruments, lights and switches .................5-7
OPERATION...................................................6-1
Starting the engine ......................................6-1
Operating the drive select lever and
driving in reverse ...................................... 6-2
Engine break-in .......................................... 6-4
Parking ....................................................... 6-5
Parking on a slope ..................................... 6-5
Accessories and loading ............................ 6-5
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT............................................ 7-2
BE CAREFUL WHERE YOU RIDE............. 7-9
TURNING YOUR ATV .............................. 7-13
CLIMBING UPHILL ................................... 7-14
RIDING DOWNHILL.................................. 7-17
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH SHALLOW
WATER ................................................... 7-19
RIDING OVER ROUGH TERRAIN ........... 7-22
SLIDING AND SKIDDING ......................... 7-22
WHAT TO DO IF... .................................... 7-23
WHAT TO DO... ........................................ 7-23
PERIODIC MAINTENANCE AND MINOR
REPAIR .......................................................... 8-1
Owner’s manual and tool kit ....................... 8-1
Periodic maintenance chart for the
emission control system ...........................8-3
General maintenance and lubrication
chart ..........................................................8-4
Removing and installing panels ..................8-8
Removing the radiator grills ......................8-19
Checking the spark plug ...........................8-20
Engine oil and oil filter cartridge ................8-22
Final gear oil .............................................8-26
Differential gear oil ....................................8-29
Coolant .....................................................8-31
Cleaning the air filter element ...................8-37
Cleaning the spark arrester ......................8-41
V-belt case drain plug ...............................8-43
Adjusting the throttle cable free play .........8-43
Valve clearance ........................................8-44
Adjusting the drive select lever safety
system cable ...........................................8-44
Checking the front and rear brake pads ...8-44
Checking the rear brake hose
protectors ................................................8-45
Checking the brake fluid level ...................8-46
Changing the brake fluid ...........................8-47
Checking the front and rear brake lever
free play ..................................................8-48
Adjusting the brake pedal free play ..........8-49
Axle boots .................................................8-51
Checking and lubricating the cables ........ 8-52
Checking and lubricating the front and
rear brake levers .................................... 8-52
Checking and lubricating the brake
pedal ...................................................... 8-53
Checking the wheel hub bearings ............ 8-53
Checking the stabilizer bushes ................ 8-53
Lubricating the rear knuckle pivots ........... 8-54
Lubricating the steering shaft ................... 8-54
Battery ...................................................... 8-54
Replacing a fuse ...................................... 8-57
Replacing a headlight bulb ....................... 8-59
Adjusting a headlight beam ...................... 8-62
Replacing the tail/brake light bulb ............ 8-62
Removing a wheel .................................... 8-63
Installing a wheel ...................................... 8-64
Troubleshooting ....................................... 8-65
Troubleshooting charts ............................. 8-66
CLEANING AND STORAGE.......................... 9-1
Cleaning ..................................................... 9-1
Storage ....................................................... 9-2
SPECIFICATIONS ...................................... 10-1
CONSUMER INFORMATION ...................... 11-1
Identification numbers .............................. 11-1
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SAFETY INFORMATION
EBU27250
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.
1
● 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.
1-1
● Always inspect your ATV each time you use it to
make sure it is in safe operating condition. Al-
1
ways 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
1-2
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 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.
● 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.
EWB02330
WARNING
● Always turn off the engine when refueling.
● Do not refuel right after the engine has been
running and is still very hot.
● Do not spill gasoline on the engine or ex-
haust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of
sparks, open flames, or other sources of ig-
1
1-3
nition such as the pilot lights of water heaters and clothes dryers. Gasoline can catch
1
fire and you could be burned.
● When transporting the ATV in another vehi-
cle, be sure it is kept upright. Otherwise, fuel
may leak out of the fuel tank.
● Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gasoline
vapor, or get some gasoline in your eyes,
seek medical help immediately. If gasoline
spills on your skin, wash with soap and water. If gasoline spills on your clothing,
change your clothes.
EWB00070
WARNING
Always operate your ATV in an area with adequate ventilation. Never start or run the engine
in a closed area. Exhaust fumes are poisonous
and may cause loss of consciousness and
death within a short time.
1-4
EBU17660
LOCATION OF THE WARNING AND SPECIFICATION LABELS
2
2-1
EBU27150
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 replace-
2
ment label from your Yamaha dealer.
For Europe and Oceania
2-2
For Europe
2
2-3
For Europe
2
2-4
For Europe
2
2-5
For Oceania
2
2-6
For Oceania
2
2-7
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DESCRIPTION
EBU17690
Left view
3
1. Radiator cap
2. Battery
3. Fuses
4. Air filter case
5. Spark arrester
6. Engine oil dipstick
7. Oil filter cartridge
8. Coolant reservoir
EBU17700
Right view
1. Rear shock absorber assembly spring preload adjusting
ring
2. Rear storage compartment and tool kit
3. Fuel tank cap cover
4. Front shock absorber assembly spring preload adjusting
ring
5. Spark plug
6. Brake pedal
7. V-belt case drain plug
3-1
EBU17712
Controls and instruments
1. Drive select lever
2. Rear brake lever
3. Handlebar switches
4. Horn switch
5. Rear brake fluid reservoir
6. Multifunction display
7. Front brake fluid reservoir
8. On-Command four-wheel-drive/differential gear lock
switch
9. Front brake lever
10.Throttle lever
11.Front storage compartment
12.Main switch
13.Auxiliary DC jack
TIP
The ATV you have purchased may differ slightly
from the figures shown in this manual.
3
3-2
EBU17732
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. Main switch
4-1
EBU26692
Indicator lights and warning lights
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. Engine trouble warning light “”
9. Coolant temperature warning light “”
10.Electric Power Steering warning light “EPS”
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Reverse indicator light “”
This indicator light comes on when the transmission is in the reverse position.
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Neutral indicator light “”
This indicator light comes on when the transmission is in the neutral position.
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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.
The electrical circuit of the warning light can be
checked by turning the key to “ON”. If the warning
light does not come on, have a Yamaha dealer
check the electrical circuit.
ECB00891
NOTICE
● The engine may overheat if the ATV is over-
loaded. In this case, reduce the load to specification.
4
4-2
● The engine may also overheat if mud or dirt
has accumulated on the radiator (i.e., after
riding in wet terrain). In this case, see page
8-19 for an explanation on how to access the
radiator.
● Start the engine after making sure that the
warning light is out. Continuous use while
the warning light is on may cause damage to
4
the engine.
EBU27280
Engine trouble warning light “”
This warning light comes on or flashes when an
electrical circuit monitoring the engine is defective.
When this occurs, have a Yamaha dealer check
the self-diagnosis system. (See page 4-5 for an explanation of the self-diagnosis device.)
The electrical circuit of the warning light can be
checked by turning the key to “ON”. If the warning
light does not come on, then go off, have a
Yamaha dealer check the electrical circuit.
EBU27542
Electric Power Steering warning light “EPS”
This warning light comes on when the key is turned
to “ON”, and then goes off once the engine is started. If the warning light remains on or comes on af-
ter the engine is started, the EPS system may be
defective. When this occurs, have a Yamaha dealer check the EPS system.
The electrical circuit of the warning light can be
checked by turning the key to “ON”. If the warning
light does not come on, have a Yamaha dealer
check the electrical circuit.
TIP
● If the engine is stopped using the engine stop
switch and the key is in the “ON” position, the
EPS warning light comes on to indicate that the
power assistance for the steering is not functioning.
● If the steering load is too heavy (i.e., excessive
steering use when the ATV is traveling at a slow
speed), the power assist is reduced to protect
the EPS motor from overheating.
EBU17961
On-Command four-wheel-drive/differential
gear lock indicator “”/“”
The On-Command four-wheel-drive indicator “”
comes on when the On-Command four-wheeldrive switch is set to the “4WD” position.
4-3
The On-Command differential gear lock
indicator “” in the On-Command four-wheel-
drive indicator also comes 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 “” will
flash until the differential gear is locked.
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Park indicator light “”
This indicator light comes on when the transmission is in the park position.
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High-range indicator light “”
This indicator light comes on when the transmission is in the high-range position.
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Low-range indicator light “”
This indicator light comes on when the transmission is in the low-range position.
EBU18001
On-Command differential gear lock indicator
light “DIFF. LOCK”
This indicator light and the On-Command differential gear lock indicator in the display come on when
the On-Command differential gear lock switch is
set to the “LOCK” position.
TIP
When the switch is set to “LOCK”, the On-Command differential gear lock indicator light will flash
until the differential gear is locked.
4
4-4
EBU27293
Multifunction display
4
1. “CLOCK” button
2. “RESET” button
3. “SELECT” button
4. Speedometer
5. Fuel meter
6. Clock/Hour meter
7. Odometer/Tripmeter A/Tripmeter B
The multifunction display is equipped with the following:
● a speedometer (which shows the riding speed)
● an odometer (which shows the total distance
traveled)
● two tripmeters (which show the distance trav-
eled since they were last set to zero)
● a clock
● an hour meter (which shows the total time the
engine has been running)
● a fuel meter
● a self-diagnosis device
Odometer and tripmeter modes
Pushing the “SELECT” button switches the display
between the odometer mode “ODO” and the tripmeter modes “A” and “B” in the following order:
ODO → TRIP A → TRIP B → ODO
To reset a tripmeter, select it by pushing the “SE-
LECT” button, and then push the “RESET” button
for at least three seconds. The tripmeters can be
used to estimate the distance that can be traveled
with a full tank of fuel. This information will enable
you to plan future fuel stops.
TIP
Pushing and holding in the “SELECT” button, and
turning the key to “ON” while the button is pushed,
switches the display between “mph” and “km/h”.
Clock mode
Pushing the “CLOCK” button switches the display
between the clock mode “CLOCK” and the hour
meter mode “HOUR” in the following order:
4-5
CLOCK → HOUR → CLOCK
To set the clock
1. Set the display to the clock mode.
2. Push the “SELECT” button and “RESET” button together for at least three seconds.
3. When the hour digits start flashing, push the
“RESET” button to set the hours.
4. Push the “SELECT” button, and the minute
digits will start flashing.
5. Push the “RESET” button to set the minutes.
6. Push the “SELECT” button and then release it
to start the clock.
Fuel meter
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as the
fuel level decreases. When the “E” segment disappears and the fuel level warning indicator flashes,
refuel as soon as possible.
TIP
This fuel meter is equipped with a self-diagnosis
system. If the electrical circuit is defective, all the
display segments and fuel level warning indicator
will start flashing. If this occurs, have a Yamaha
dealer check the electrical circuit.
4
1. Fuel level warning indicator
2. Fuel meter
3. “E” segment
4-6
Self-diagnosis device
4
EBU18061
Handlebar switches
1. Error code display
This model is equipped with a self-diagnosis device for various electrical circuits.
If any of those circuits are defective, the multifunction display will indicate a two-digit error code.
If the multifunction display indicates such an error
code, note the code number, and then have a
Yamaha dealer check the vehicle.
ECB00810
NOTICE
If the multifunction display indicates an error
code, the vehicle should be checked as soon
as possible in order to avoid engine damage.
1. Light switch “ / /OFF”
2. Start switch “”
3. Engine stop switch “ / ”
4. Override switch “OVERRIDE”
5. Horn switch “”
EBU18080
Engine stop switch “ / ”
Set this switch to “” before starting the engine.
The engine stop switch controls the ignition and
stops the engine when it is running. Use this switch
to stop the engine in an emergency situation. The
engine will not start or run when this switch is set
to “”.
4-7
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