8-42
8
WARNING
EWB02160Battery electrolyte is poisonous and danger-
ous, as it contains sulfuric acid, which can
cause severe burns. Avoid contact with skin,
eyes or clothing. Always shield your eyes
when working near batteries.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg
or vegetable oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of ig-
nition away. Ventilate when charging or using
in an enclosed space.
KEEP OUT OF REACH OF CHILDREN.To remove the battery
1. Remove the seat. (See page 4-13.)
2. Remove the battery holding plate by removing
the bolts.3. Disconnect the negative battery lead first,
then the positive battery lead by removing
their bolt. NOTICE: When removing the bat-
tery, the main switch must be off, and the
negative lead must be disconnected be-
fore the positive lead.
[ECB01001]
4. Pull the battery out of its compartment.1. Negative battery lead (black)
2. Positive battery lead (red)
21
U1AS60E0.book Page 42 Friday, February 6, 2009 1:27 PM
8-45
8
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off all electrical
circuits.
NOTICEECB00640To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse.
2. Remove the blown fuse, and then install a
new fuse of the specified amperage.
WARNING! Always use a fuse of the spec-
ified rating, and never use a substitute ob-
ject in place of the proper fuse. An
improper fuse or a substitute object can
cause damage to the electrical system,
which could lead to a fire.
[EWB02172]
3. Turn the key to “ON” and turn on the electrical
circuits to check if the devices operate.
4. If the fuse immediately blows again, have a
Yamaha dealer check the electrical system.
1. Signaling system fuse
2. Headlight fuse
3. Ignition fuse
4. Fuel injection system fuse
5. Spare fuse
1
2
3
4 5
Specified fuses:
Main fuse:
20.0 A
Headlight fuse:
15.0 A
Ignition fuse:
10.0 A
Signaling system fuse:
10.0 A
Fuel injection system fuse:
10.0 A
U1AS60E0.book Page 45 Friday, February 6, 2009 1:27 PM
8-49
8
TIPWhen installing the wheel, make sure its arrow
mark points toward the rotating direction of the
wheel.3. Lower the ATV to the ground.
4. Tighten the wheel nuts to the specified
torques.
EBU25740Troubleshooting Although Yamaha ATVs receive a thorough in-
spection before shipment from the factory, trouble
may occur during operation. Any problem in the fu-
el, compression, or ignition systems, for example,
can cause poor starting and loss of power.
The following troubleshooting charts represent
quick and easy procedures for checking these vital
systems yourself. However, should your ATV re-
quire any repair, take it to a Yamaha dealer, whose
skilled technicians have the necessary tools, expe-
rience, and know-how to service the ATV properly.
Use only genuine Yamaha replacement parts. Im-
itation parts may look like Yamaha parts, but they
are often inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWB02280Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe inju-
ry or property damage. Make sure there are no
open flames or sparks in the area, including pi-
lot lights from water heaters or furnaces.
1. Arrow markTightening torques:
Front wheel nut:
45 Nm (4.5 m·kgf, 32 ft·lbf)
Rear wheel nut:
45 Nm (4.5 m·kgf, 32 ft·lbf)
U1AS60E0.book Page 49 Friday, February 6, 2009 1:27 PM
8-51
8Engine overheating
WARNING
EWB02290Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by
hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening.
Allow any remaining pressure to escape before completely removing the cap.TIPIf coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec-
ommended coolant as soon as possible.Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer check
and repair the cooling system.Add coolant. (See TIP.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
U1AS60E0.book Page 51 Friday, February 6, 2009 1:27 PM
9-1
9
EBU25860
CLEANING AND STORAGE
EBU25901Cleaning Frequent, thorough cleaning of your ATV will not
only enhance its appearance but will improve its
general performance and extend the useful life of
many components.
1. Before cleaning the ATV:
a. Block off the end of the exhaust pipe to
prevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plug and all filler caps
are properly installed.
2. If the engine case is excessively greasy, apply
degreaser with a paint brush. Do not apply de-
greaser to the chain, sprockets or wheel ax-
les.
3. Rinse the dirt and degreaser off with a garden
hose. Use only enough pressure to do the job.
WARNING! Wet brakes may have reduced
stopping ability, increasing the chance of
an accident. Test the brakes after washing.
Apply the brakes several times at slow
speeds to let friction dry out the linings.
[EWB02311]
NOTICE: Excessive water pressuremay cause water seepage and deteriora-
tion of wheel bearings, brakes, transmis-
sion seals and electrical devices. Many
expensive repair bills have resulted from
improper high-pressure detergent applica-
tions such as those available in coin-oper-
ated car washers.
[ECB00711]
4. Once most of the dirt has been hosed off,
wash all surfaces with warm water and mild,
detergent-type soap. An old toothbrush or bot-
tle brush is handy for hard-to-reach places.
5. Rinse the ATV off immediately with clean wa-
ter and dry all surfaces with a chamois, clean
towel or soft absorbing cloth.
6. Dry the chain and lubricate it to prevent it from
rusting.
7. Clean the seat with a vinyl upholstery cleaner
to keep the cover pliable and glossy.
8. Automotive type wax may be applied to all
painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protec-
tive finish. When finished cleaning, start the
engine and let it idle for several minutes.
U1AS60E0.book Page 1 Friday, February 6, 2009 1:27 PM
10-4
10
Front brake:Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4Rear brake:Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4Front suspension:Type:
Double wishbone
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
230 mm (9.1 in)Rear suspension:Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
256 mm (10.1 in)Electrical system:Ignition system:
TCI (digital)Charging system:
AC magneto
Battery:Model:
GT9B-4
Voltage, capacity:
12 V, 8.0 AhHeadlight:Bulb type:
Krypton bulbBulb voltage, wattage × quantity:Headlight:
12 V, 30/30 W × 2
Tail/brake light:
LED
Meter lighting:
EL
Neutral indicator light:
LED
Fuel level warning light:
LED
Reverse indicator light:
LED
Coolant temperature warning light:
LED
Engine trouble warning light:
LEDFuses:Main fuse:
20.0 A
U1AS60E0.book Page 4 Friday, February 6, 2009 1:27 PM
INDEX
AAccessories and loading ................................................ 6-7
Air filter element, cleaning ............................................ 8-20BBattery .......................................................................... 8-41
Brake and clutch levers, checking and lubricating ....... 8-38
Brake fluid, changing .................................................... 8-31
Brake fluid level, checking ............................................ 8-29
Brake lever ..................................................................... 4-8
Brake lever free play, checking the front ...................... 8-31
Brake light switches ..................................................... 8-33
Brake pads, checking the front and rear ...................... 8-28
Brake pedal .................................................................... 4-8
Brake pedal, checking and lubricating ......................... 8-39
Brake pedal position, checking .................................... 8-32
Brakes .......................................................................... 8-28
Brakes, front and rear .................................................... 5-3CCables, checking and lubricating ................................. 8-38
Chassis fasteners ........................................................... 5-6
Cleaning ......................................................................... 9-1
Clutch lever .................................................................... 4-7
Clutch lever free play, adjusting ................................... 8-34
Coolant .................................................................. 5-3, 8-17
Coolant temperature warning light ................................. 4-2DDrive chain ..................................................................... 5-4
Drive chain, lubricating ................................................. 8-37Drive chain slack .......................................................... 8-35
EEngine break-in .............................................................. 6-5
Engine idling speed ...................................................... 8-26
Engine oil ....................................................................... 5-3
Engine oil and oil filter element .................................... 8-12
Engine, start ................................................................... 6-1
Engine stop switch ......................................................... 4-5
Engine trouble warning light ........................................... 4-3FFuel ....................................................................... 4-11, 5-3
Fuel level warning light ................................................... 4-3
Fuel tank cap ................................................................ 4-11
Fuses, replacing ........................................................... 8-44HHandlebar switches ........................................................ 4-5
Headlight beam, adjusting ............................................ 8-47
Headlight bulb, replacing .............................................. 8-46IIdentification numbers .................................................. 11-1
Indicator lights and warning lights .................................. 4-2
Instruments, lights and switches .................................... 5-6KKey identification number ............................................. 11-1LLabel locations ............................................................... 1-1
Light switch .................................................................... 4-6
U1AS60E0.book Page 1 Friday, February 6, 2009 1:27 PM