Yamaha YFM45FGW Owner's Manual

READ THIS MANUAL CAREFULLY!It contains important safety information.This ATV should not be ridden by anyone under 16 years of age.WARNINGOWNER’S MANUA

1-21● Always inspect your ATV each time you use it tomake sure it is in safe operating condition. Al-ways follow the inspection and maintenanceprocedu

8-7821Engine oil filter car-tridge• Replace. √√√22 * Engine oil strainer • Clean. √√√23 Differential gear oil• Change.• Check ATV for oil leakage, and

8-88EBU23070NOTE:● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.● Hydraulic brake service• Regularly c

8-98WARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.EBU23090Removing and installing panels The panels shown ne

8-108To install one of the panels1. Place the panel in its original position.U1D913E0.book Page 10 Thursday, April 20, 2006 2:47 PM

8-1182. Install the seat.Panel BTo remove the panelRemove the bolt, and then take the panel off.To install the panelPlace the panel in the original po

8-128Panel CTo remove the panel1. Remove the carrier top bolts.2. Remove the carrier bolts under the fenders,and then take the carrier off.3. Remove t

8-138To install the panel1. Place the panel in the original position, andthen install the quick fastener screws.2. Place the carrier in the original p

8-148To install the panelPlace the panel in its original position.EBU23221Checking the spark plug The spark plug is an important engine component,whic

8-1583. Remove the spark plug as shown, with thespark plug wrench included in the owner’s toolkit.To check the spark plug1. Check that the porcelain i

8-1682. Clean the surface of the spark plug gasketand its mating surface, and then wipe off anygrime from the spark plug threads.3. Install the spark

1-31steady speed when climbing a hill. If you stall orroll backwards, follow the special procedure forbraking described in this manual. Dismount onthe

8-1786. Insert the dipstick into the filler hole (withoutscrewing it in), and then remove it again tocheck the oil level.NOTE:The engine oil should be

8-188To change the engine oil (with or without oil fil-ter cartridge replacement)1. Remove panel F. (See page 8-9.)2. Place the ATV on a level surface

8-198NOTE:An oil filter wrench is available at a nearby Yamahadealer.8. Apply a thin coat of engine oil to the O-ring ofthe new oil filter cartridge.N

8-20810. Install panels E and D.11. Install the engine oil drain bolt, and then tight-en it to the specified torque.12. Add the specified amount of th

8-21813. Start the engine, and then let it idle for severalminutes while checking it for oil leakage. If oilis leaking, immediately turn the engine of

8-228To change the final gear oil1. Remove the engine guard and the final gearcase guard by removing the bolts.2. Place the ATV on a level surface.3.

8-238CAUTION:ECB00420Be sure no foreign material enters the finalgear case.7. Install the oil filler bolt, and then tighten it to thespecified torque.

8-248To check the differential gear oil level1. Place the ATV on a level surface.NOTE:The differential gear oil level must be checked ona cold engine.

8-2584. Install the drain bolt, and then tighten it to thespecified torque.5. Add the recommended differential gear oil tothe brim of the filler hole

8-2687. Check the differential gear case for oil leak-age. If oil is leaking, check for the cause.EBU23470Coolant The coolant level should be checked

1-41WARNINGEWB00021WARNINGEWB00030POTENTIAL HAZARDImproper handling of gasoline.WHAT CAN HAPPENGasoline can catch fire and you could beburned.HOW TO A

8-278CAUTION:ECB00401● If coolant is not available, use distilled wateror soft tap water instead. Do not use hard wa-ter or salt water since it is har

8-2884. Remove the front carrier and panel C. (Seepage 8-9.)5. Remove the radiator cap.6. Remove panel D. (See page 8-9.)7. Remove the coolant reservo

8-2989. After draining the coolant, thoroughly flush thecooling system with clean tap water.10. Replace the coolant drain bolt washer if it isdamaged,

8-308● If water has been added to the coolant, havea Yamaha dealer check the antifreeze con-tent of the coolant as soon as possible, oth-erwise the ef

8-3183. Pull the air filter element out of the air filtercase.4. Pull off the lock plate, and then remove thesponge material from the air filter eleme

8-3285. Wash the sponge material gently but thor-oughly in solvent.WARNINGEWB019006. Squeeze the excess solvent out of the spongematerial and let it d

8-338NOTE:The air filter element should be cleaned every 20–40 hours. It should be cleaned and lubricated moreoften if the ATV is operated in extremel

8-3484. Insert the tailpipe into the muffler and align thebolt holes.5. Install and tighten the bolts.WARNINGEWB01910EBU23920V-belt cooling duct check

8-358EBU23930V-belt case drain plug After riding in water deep enough to allow it to en-ter the V-belt case, remove this plug to drain thewater from t

8-368CAUTION:ECB00480The carburetor has been set and extensivelytested at the Yamaha factory. Changing thesesettings without sufficient technical know

1-51WHAT CAN HAPPENExhaust fumes are poisonous and maycause loss of consciousness and deathwithin a short time.HOW TO AVOID THE HAZARDAlways operate y

8-3785. Install the panel.EBU24043Adjusting the throttle cable free play The throttle cable free play should be checkedand, if necessary, adjusted at

8-388EBU24070Adjusting the drive select lever safety system cable The drive select lever safety system cable stretch-es with use, which can result in

8-398that the wear indicator grooves have almost disap-peared, have a Yamaha dealer replace the brakepads as a set.NOTE:The wheels need to be removed

8-408Rear brakeNOTE:To check the rear brake fluid level, remove panelC. (See page 8-9.)Observe these precautions:● When checking the fluid level, make

8-418EBU24380Checking the front brake lever free play The brake lever free play must be checked at theintervals specified in the periodic maintenance

8-428● Before adjusting the brake lever free play andchecking the brake pedal position, check therear brake pads for wear.Adjusting the brake lever fr

8-438Checking the brake pedal positionThe top of the brake pedal should be positioned72.0 mm (2.83 in) above the top of the footboard.If the brake ped

8-448EBU24751Brake light switches The operation of the brake light switches must bechecked and, if necessary, adjusted at the inter-vals specified in

8-4583. Install the panel.EBU24890Checking and lubricating the cables The operation and the condition of all control ca-bles should be checked before

8-468EBU24950Checking and lubricating the brake pedal The operation of the brake pedal should bechecked before each ride, and the pedal pivotshould be

2-12EBU17660LOCATION OF THE WARNING AND SPECIFICATION LABELS U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM

8-478EBU25021Checking the stabilizer bushes The stabilizer bushes must be checked for cracksor damage at the intervals specified in the periodicmainte

8-488EBU25100Lubricating the steering shaft The steering shaft must be lubricated at the inter-vals specified in the periodic maintenance and lu-brica

8-498To store the battery1. If the ATV will not be used for more than onemonth, remove the battery, fully charge it, andthen place it in a cool, dry p

8-508EBU25313Replacing a fuse 1. Main fuse2. Fuse box1. Main fuse2. Spare main fuseU1D913E0.book Page 50 Thursday, April 20, 2006 2:47 PM

8-518The main fuse and the fuse box are located underthe seat. (See page 4-19.)If a fuse is blown, replace it as follows.1. Turn the key to “OFF” and

8-528WARNINGEWB021513. Turn the key to “ON” and turn on the electricalcircuits to check if the devices operate.4. If the fuse immediately blows again,

8-5383. Remove the headlight bulb holder assemblyby turning it counterclockwise.NOTE:The headlight bulb cannot be removed from theheadlight bulb holde

8-548CAUTION:ECB00650Do not touch the glass part of the headlightbulb to keep it free from oil, otherwise thetransparency of the glass, the luminosity

8-5582. Remove the bulb holder (together with thebulb) by turning it counterclockwise.3. Remove the defective bulb by pushing it inand turning it coun

8-5684. Insert a new bulb into the bulb holder, push itin, and then turn it clockwise until it stops.5. Install the bulb holder (together with the bul

2-22EBU17670Read and understand all of the labels on your ATV. These labels contain important information for safe andproper operation.Never remove an

8-578● Tapered nuts are used for both the front and rearwheels. Install the nuts with their tapered side to-wards the wheel.2. Lower the ATV to the gr

8-588EBU25730Troubleshooting Although Yamaha ATVs receive a thorough in-spection before shipment from the factory, troublemay occur during operation.

8-598EBU25771Troubleshooting charts Starting problems or poor engine performanceCheck the fuel level inthe fuel tank.1. FuelThere is enough fuel.There

8-608Engine overheatingWARNINGEWB02270NOTE:If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the

9-19EBU25860CLEANING AND STORAGEEBU25870Cleaning Frequent, thorough cleaning of your ATV will notonly enhance its appearance but will improve itsgener

9-29EBU25932Storage Short-termAlways store your ATV in a cool, dry place and, ifnecessary, protect it against dust with a porouscover.CAUTION:ECB00720

9-39c. Install the spark plug cap onto the sparkplug, and then place the spark plug on thecylinder head so that the electrodes aregrounded. (This will

10-110EBU25960SPECIFICATIONS Dimensions:Overall length:1993 mm (78.5 in)Overall width:1093 mm (43.0 in)Overall height:1120 mm (44.1 in)Seat height:830

10-210With oil filter cartridge replacement:2.40 L (2.54 US qt) (2.11 Imp.qt)Final gear oil:Type:SAE80 API GL-4 Hypoid gear oilQuantity:0.16 L (0.17 U

10-310Caster angle:2.5 °Trail:8.5 mm (0.33 in)Front tire:Type:TubelessSize:AT25 x 8-12Manufacturer/model:MAXXIS/M979Rear tire:Type:TubelessSize:AT25 x

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10-410Front suspension:Type:Double wishboneSpring/shock absorber type:Coil spring/oil damperWheel travel:160 mm (6.3 in)Rear suspension:Type:Double wi

10-510Four-wheel-drive motor fuse:3.0 AU1D913E0.book Page 5 Thursday, April 20, 2006 2:47 PM

11-111EBU25981CONSUMER INFORMATIONEBU26011Identification numbers Record the key identification number, vehicle iden-tification number and model label

11-211NOTE:The vehicle identification number is used to identifyyour ATV.EBU26050Model label The model label is affixed at the location in the il-lust

11-311EBU26060Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:Federal law prohibits the following acts or the causing thereof: (1) The

11-411EBU26080Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main-tenance do

11-511EBU26501YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased fr

11-611WARRANTY QUESTIONS AND ANSWERSQ. What costs are my responsibility during the warranty period?A. The customer’s responsibility includes all costs

11-711EBU26122YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S

11-811We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-b

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11-911EBU26132U1D913E0.book Page 9 Thursday, April 20, 2006 2:47 PM

INDEXAAccessories and loading ... 6-6Accessories, auxiliary jack ...

IIdentification numbers ... 11-1Indicator lights and warning light ...

VValve clearance ... 8-37V-belt case drain plug ...

YAMAHA MOTOR CO., LTD.EBU26151LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.(For replacement manual, call 1-800-532-1558)WARNIN

3-13EBU17680DESCRIPTION EBU17690Left viewEBU17700Right view1. Radiator cap2. Fuel cock3. Recoil starter4. Throttle stop screw5. Air filter case6. Batt

3-23EBU17712Controls and instrumentsNOTE:The ATV you have purchased may differ slightlyfrom the figures shown in this manual.1. Rear brake lever2. Han

EBU17091U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM

4-14EBU17720INSTRUMENT AND CONTROL FUNCTIONSWARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.EBU17760Main switc

4-24EBU17812Indicator lights and warning light EBU17840Reverse indicator light “” This indicator light comes on when the transmis-sion is in the rever

4-34EBU17961On-Command four-wheel-drive/differential gear lock indicator “”/“” The On-Command four-wheel-drive indicator “”comes on when the On-Comman

4-44EBU18031Multifunction display The speedometer unit is equipped with the follow-ing:● a speedometer (which shows the riding speed)● an odometer (wh

4-54To set the clock1. Set the display to the clock mode.2. Push the “”/“” button until the clock startsflashing.3. Set the hours by pushing the “H” b

4-64EBU18080Engine stop switch “ / ” Set this switch to “” before starting the engine.The engine stop switch controls the ignition andstops the engine

4-74switch to override the differential gear lock speedlimiting function. (See page 4-9.) Releasing theswitch restores the speed limiting function.Whi

4-84● “4WD” (four-wheel drive): Power is supplied tothe rear and front wheels.To change from two-wheel drive to four-wheeldrive, stop the ATV and push

4-94EBU18243On-Command differential gear lock switch “4WD”/“LOCK” This ATV is equipped with a switch allowing you tolock the differential gear when in

4-104To release the differential gear lock, stop the ATVand push the switch to the “4WD” position.WARNINGEWB000911. On-Command differential gear lock

EBU17170INTRODUCTIONEBU17270Congratulations on your purchase of the Yamaha YFM45FGW. This ATV represents the result of manyyears of Yamaha experience

4-114WARNINGEWB00101NOTE:● When the switch is set to “LOCK”, the differentialgear lock indicator and indicator light will flashuntil the differential

4-124Before starting the engine, check the throttle to besure it is operating smoothly. Make sure it returnsto the idle position as soon as the lever

4-1343. Tighten the locknut.WARNINGEWB00190EBU18391Front brake lever The front brake lever is located on the right handle-bar. To apply the front brak

4-144EBU18442Brake pedal and rear brake lever The brake pedal is located on the right side of theATV and the rear brake lever is located on the leftha

4-154EBU18680Recoil starter Firmly grasp the handle and pull slightly until en-gagement can be felt. Then pull forcefully, beingcareful not to pull th

4-164EBU18720Fuel tank cap Remove the fuel tank cap by turning it counter-clockwise.EBU18730Fuel Make sure that there is sufficient fuel in the tank.F

4-174CAUTION:ECB00070Use only unleaded gasoline. The use of leadedgasoline will cause severe damage to internalengine parts, such as the valves and pi

4-184OFFWith the fuel cock lever in this position, fuel will notflow. Always turn the fuel cock lever to this positionwhen the engine is not running.O

4-194RESThis indicates reserve. With the fuel cock lever inthis position, the fuel reserve is made available.Turn the fuel cock lever to this position

4-204To install the seatInsert the projections on the front of the seat intothe seat holders and push down on the seat at therear.NOTE:Make sure that

EBU17330IMPORTANT MANUAL INFORMATIONEBU17341FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN-JURY OR DEATH.Particularl

4-214CAUTION:ECB00130Do not store metal or sharply edged objects,like tools, in the storage compartment. If theymust be stored, wrap them in appropria

4-224EBU18970Rear carrier ● Do not exceed the load limit of 80.0 kg (176 lb)for the rear carrier.● Do not exceed the maximum load of 210.0 kg(463 lb)

4-234WARNINGEWB00350EBU19180Auxiliary DC jack The auxiliary DC jack is located at the front rightside of the ATV. The auxiliary DC jack can be usedfor

4-2444. When the auxiliary DC jack is not being used,cover it with the cap.CAUTION:ECB00120● Do not use accessories requiring more thanthe above maxim

5-15EBU19200PRE-OPERATION CHECKSEBU19210Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table.N

5-25Rear brake• Check operation. If soft or spongy, have Yamaha dealer bleed hy-draulic system.• Check lever free play, and adjust if necessary.• Chec

5-35WARNINGEWB00470POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENIncreases the possi

5-45EBU19530Fuel Make sure that there is sufficient fuel in the tank.(See page 4-16.)WARNINGEWB00500EBU19560Engine oil Make sure that the engine oil i

5-55WARNINGEWB00490EBU19721Front and rear brakes Brake levers and brake pedal● Check that there is no free play in the front brakelever. If there is f

5-65WARNINGEWB00540EBU19761Throttle lever Check the operation of the throttle lever. It mustopen smoothly and spring back to the idle positionwhen rel

EBU17350IMPORTANT NOTICEEBU17360Welcome to the Yamaha world of motor sports!This ATV is designed and manufactured for OFF-ROAD use only. It is illegal

5-75EBU19801Tires WARNINGEWB00551POTENTIAL HAZARDOperating this ATV with improper tires, orwith improper or uneven tire pressure.WHAT CAN HAPPENUse of

5-85EBU19820Measuring the tire pressure Use the low-pressure tire gauge.NOTE:The low-pressure tire gauge is included as stan-dard equipment. Make two

5-95EBU19830Tire wear limit Replace the tire when the tire groove decreases to3 mm (0.12 in).EBU19840Chassis fasteners Make sure that all nuts, bolts

6-16EBU19870OPERATIONWARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.EBU19890WARNINGEWB00610EBU20042Starting a

6-263. Shift the drive select lever into the neutral orpark position. The corresponding indicatorlight should come on. If the indicator light doesnot

6-36● If the battery is discharged, pull the recoil starterto start the engine.7. If the engine is started with the starter (choke)in position (1), th

6-463. Release the brake pedal, and then open thethrottle lever gradually.Shifting: Neutral to Reverse and Reverse toParkNOTE:The drive select lever c

6-56● Due to the synchronizing mechanism in the en-gine, the indicator light may not come on until theATV starts moving.4. Check behind for people or

6-66EBU20690Parking When parking the ATV, stop the engine, shift thedrive select lever into the park position, and thenturn the fuel cock to the “OFF”

6-76it is not possible for Yamaha to test all non-Yamaha accessories, nor control over their qual-ity or suitability. Choose a genuine Yamaha ac-cesso

WARNINGEWB00010Indicates a potential hazard that could resultin serious injury or death.EBU17420TABLE OF CONTENTSSAFETY INFORMATION ...

6-86the weight on the hitch. If you are carrying cargoand towing a trailer, include the tongue weight inthe maximum ATV load limit.● Load cargo on the

7-17EBU21131RIDING YOUR ATV U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM

7-27WARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.EBU21471GETTING TO KNOW YOUR ATVThis ATV is for recreation

7-37Riding your ATV requires skills acquiredthrough practice over a period of time.Take the time to learn the basic techniques wellbefore attempting m

7-47This ATV is designed to carry operator and car-go only – passengers prohibited.WARNINGEWB00910POTENTIAL HAZARDCarrying a passenger on this ATV.WHA

7-57ApparelWARNINGEWB00920POTENTIAL HAZARDOperating this ATV without wearing an ap-proved motorcycle helmet, eye protectionand protective clothing.WHA

7-67Do not operate after consuming alcohol ordrugs.The operator’s performance capability is reducedby the influence of alcohol or drugs.WARNINGEWB0093

7-77WARNINGEWB00950WARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.Do not operate at speeds too fast for your

7-87Speed limiterFor riders less experienced with this model, thethrottle lever housing is equipped with a speed lim-iter. The speed limiter keeps the

7-97WARNINGEWB00970POTENTIAL HAZARDOverloading this ATV or carrying or towingcargo improperly.WHAT CAN HAPPENCould cause changes in ATV handling which

Tires ... 5-7Measuring the tire pressure ... 5-8Tire wear limit ...

7-107During operationAlways keep your feet on the footboards during op-eration, otherwise they may contact the rearwheels.WARNINGEWB00980Avoid wheelie

7-117ModificationsWARNINGEWB01000POTENTIAL HAZARDOperating this ATV with improper modifica-tions.WHAT CAN HAPPENImproper installation of accessories o

7-127Exhaust systemThe exhaust system on the ATV is very hot duringand following operation. To prevent burns, avoidtouching the exhaust system. Park t

7-137Do not ride on any public road, street, or highway.Riding on public roads can result in collisions withother vehicles.WARNINGEWB01030HOW TO AVOID

7-147Know the terrain where you ride. Ride cautiously inunfamiliar areas. Stay alert for holes, rocks, orroots in the terrain, and other hidden hazard

7-157When riding in an area where you might not easilybe seen, such as desert terrain, mount a cautionflag on the ATV. DO NOT use the flag pole bracke

7-167Do not ride in areas posted “no trespassing”.Do not ride on private property without getting per-mission.Select a large, flat area off-road to be

7-177TURNING YOUR ATVTo achieve maximum traction while riding off-roadin 2WD or 4WD, the two rear wheels turn togetherat the same speed. Furthermore,

7-187As you approach a curve, slow down and begin toturn the handlebars in the desired direction. As youdo so, put your weight on the footboard to the

7-197oped your skill. In all cases avoid inclines with slip-pery or loose surfaces, or obstacles that mightcause you to lose control.WARNINGEWB01090PO

Adjusting the drive select lever safety system cable ... 8-38Checking the front and rear brake pads ...

7-207It is important when climbing a hill to make surethat your weight is transferred forward on the ATV.This can be accomplished by leaning forward a

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7-227If you are climbing a hill and you find that you havenot properly judged your ability to make it to thetop, you should turn the ATV around while

7-237If you start to roll backwards, DO NOT apply eitherbrake abruptly. If you are in 2WD, apply only thefront brake. If you are in 4WD or 4WD-LOCK, b

7-247RIDING DOWNHILLWhen riding your ATV downhill, shift your weightas far to the rear and uphill side of the ATV as pos-sible. Move back on the seat

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7-267CROSSING A SLOPETraversing a sloping surface on your ATV requiresyou to properly position your weight to maintainproper balance. Be sure that you

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7-287CROSSING THROUGH SHALLOW WATERThe ATV can be used to cross slow moving, shal-low water of up to a maximum of 35 cm (14 in) indepth. Before enteri

7-297CAUTION:ECB00280After riding your ATV in water, be sure to drainthe trapped water by removing the check hoseat the bottom of the air filter case,

1-11EBU17430SAFETY INFORMATIONEBU17482AN ATV IS NOT A TOY AND CAN BE HAZARD-OUS TO OPERATE.An ATV handles differently from other vehicles, in-cluding

7-307RIDING OVER ROUGH TERRAINRiding over rough terrain should be done with cau-tion. Look out for obstacles which could causedamage to the ATV or cou

7-317SLIDING AND SKIDDINGCare should be used when riding on loose or slip-pery surfaces since the ATV may slide. If unex-pected and uncorrected, slidi

7-327If the rear wheels of your ATV start to slide side-ways, control can usually be regained (if there isroom to do so) by steering in the direction

7-337WHAT TO DO...● If your ATV doesn’t turn when you want it to:Bring the ATV to a stop and practice the turningmaneuvers again. Be sure you are putt

8-18EBU21641PERIODIC MAINTENANCE AND MINOR REPAIREBU21660Safety is an obligation of the owner. Periodic in-spection, adjustment and lubrication will k

8-28The service information included in this manualand the tools provided in the owner’s tool kit are in-tended to assist you in the performance of pr

8-38EBU21741Periodic maintenance chart for the emission control system NOTE:● For ATVs not equipped with an odometer or an hour meter, follow the mont

8-486 * Exhaust system• Check for leakage and replace gasket(s) if neces-sary.• Check for looseness and tighten all screw clamps and joints if necessa

8-58EBU21862General maintenance and lubrication chart NO. ITEMCHECK OR MAINTENANCE JOBINITIAL EVERYWhichev-er comes firstmonth136612km (mi)320 (200)13

8-688 *Upper and lower arm pivots• Lubricate with lithium-soap-based grease. √√√9 * V-belt• Check for wear, cracks or other damage, and re-place if ne