2001 YAMAHA YFM600FWA maintenance

EBU00003
INTRODUCTION
Congratulations on your purchase of the
Yamaha YFM600FWA. 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 machine. This manual includes important
safety information. It provides information
about special techniques and skills necessary
to ride your machine. It also includes basic
maintenance and inspection procedures. If you
have any questions regarding the operation or
maintenance of your machine, please consult a
Yamaha dealer.

Switches ........................................... 5-21
Tires .................................................. 5-23
How to measure tire pressure ........ 5-27
Tire wear limit .................................. 5-29
OPERATION ........................................... 6-1
Starting a cold engine ....................... 6-3
Starting a warm engine ..................... 6-9
Warming up ........................................ 6-9
Drive select lever operation and
reverse driving ............................... 6-11
Reverse lock release wire ................ 6-15
Engine break-in ................................ 6-17
Parking .............................................. 6-19
Parking on a slope ........................... 6-21
Accessories and loading ................. 6-23
RIDING YOUR ATV ................................ 7-1
Getting to know your ATV ................. 7-3
Ride with care and good
judgement ........................................ 7-5
Be careful where you ride ............... 7-27
Turning your ATV ............................ 7-39
Climbing uphill ................................. 7-45
Riding downhill ................................ 7-55
Crossing a slope ............................... 7-59Crossing through shallow
water ............................................... 7-63
Riding over rough terrain ................ 7-67
Sliding and skidding ........................ 7-69
What to do if ..................................... 7-73
What to do ........................................ 7-73
PERIODIC MAINTENANCE AND
ADJUSTMENT ....................................... 8-1
Owner’s manual and tool kit ............. 8-3
Periodic maintenance/
lubrication ........................................ 8-7
Engine oil .......................................... 8-15
Final gear oil ..................................... 8-25
Differential gear oil .......................... 8-29
Front axle boots ............................... 8-33
Spark plug inspection ...................... 8-35
Air filter cleaning.............................. 8-39
Carburetor adjustment .................... 8-45
Idle speed adjustment ..................... 8-47
Valve clearance adjustment ............ 8-49
Throttle lever adjustment ................ 8-49
Front brake pad inspection ............. 8-51
Rear brake shoe inspection ............. 8-51
Inspecting the brake fluid level ....... 8-53
Brake fluid replacement .................. 8-57
6
7
8

Front brake lever free play
adjustment ...................................... 8-59
Rear brake pedal and lever
adjustment ...................................... 8-63
Cable inspection and
lubrication ....................................... 8-69
Brake lever and brake pedal
lubrication ....................................... 8-69
Wheel removal ................................. 8-71
Wheel installation............................. 8-73
Battery ............................................... 8-75
Battery maintenance ........................ 8-79
Fuse replacement ............................. 8-81
Headlight ........................................... 8-83
Troubleshooting ............................... 8-85
Troubleshooting chart ..................... 8-87
CLEANING AND STORAGE ................... 9-1
A. Cleaning.......................................... 9-1
B. Storage ........................................... 9-7
SPECIFICATIONS ................................. 10-1
HOW TO USE THE CONVERSION
TABLE ................................................... 11-1
9
10
11

2-5
●Always inspect your ATV each time you use
it to make sure it is in safe operating condi-
tion. Always follow the inspection and
maintenance procedures and schedules de-
scribed 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, slip-
pery or loose terrain until you have learned
and practiced the skills necessary to control
the ATV on such terrain. Always be espe-
cially cautious on these kinds of terrain.
●Always follow proper procedures for turn-
ing as described in this manual. Practice
turning at low speeds before attempting to
turn at faster speeds. Do not turn at exces-
sive speed.

5-2
5
5
5
5
5
5
5
5
9
50
55
WARNING
Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Own-
er’s Manual. Failure to inspect increases the possibility of an accident or equipment damage.

8-1
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PERIODIC MAINTENANCE AND
ADJUSTMENT
Periodic inspection, adjustment and lubrica-
tion will keep your machine in the safest and
most efficient condition possible. Safety is an
obligation of the machine owner. The most im-
portant points of machine inspection, adjust-
ment and lubrication are explained on the
following pages.
WARNING
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or can start fires. Turn off the
engine when performing maintenance unless
otherwise specified. Have a Yamaha dealer
perform service if you are not familiar with
machine service.

8-3
1. Tool kit 1. Low-pressure tire gauge
2. Owner’s manual
1. Trousse à outils 1. Manomètre basse pression pour
2. Manuel du propriétaire pneus
1. Equipo de herramientas 1.Manómetro de baja presión
2. Manual del propietario
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Owner’s manual and tool kit
You are recommended to put this owner’s
manual and low-pressure tire gauge in the vi-
nyl bag and always carry them along with the
owner’s tool kit under the seat. The service in-
formation included in this manual is intended
to provide you, the owner, with the necessary
information for completing your own preven-
tive maintenance and minor repairs. The tools
provided in the Owner’s 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.

8-7
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PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*• Check valve clearance.
• Adjust if necessary.
Spark plug• Check condition.
• Adjust gap and clean.
• Replace if necessary.
Air filter• Clean.
• Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Carburetor*• Check idle speed/starter operation.
• Adjust if necessary.
Crankcase breather
system*• Check breather hose for cracks or damage.
• Replace if necessary.
Exhaust system*• Check for leakage.
• Retighten if necessary.
• Replace gasket(s) if necessary.
Fuel line*• Check fuel hose for cracks or damage.
• Replace if necessary.
Engine oil• Replace (Warm engine before draining).
Engine oil filter• Replace.
Engine oil strainer*• Clean.
Final gear oil• Check oil level/oil leakage.
• Replace every 12 months.
Differential gear oil
Front brake*• Check operation/fluid leakage/see NOTE page 8-8.
• Correct if necessary.
Rear brake*• Check operation.
• Adjust if necessary.
V-belt*• Check operation.
• Check for cracks or damage every 12 months or
2,400 km whichever comes first.