Yamaha YFM4FGW 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

8-128Panel 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

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

1-31roll backwards, follow the special procedure forbraking described in this manual. Dismount onthe uphill side or to a side if pointed straight up-h

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.

8-2482. Place an oil pan under the differential gearcase to collect the used oil.3. Remove the differential gear oil filler bolt andthe differential g

8-258● The differential gear case capacity is greaterthan the recommended oil quantity, thereforethe oil level cannot be accurately checked fromthe oi

8-2683. If the coolant is at or below the minimum levelmark, remove panel D. (See page 8-9.)4. Remove the reservoir cap, add coolant or dis-tilled wat

8-278EBU23592To change the coolantWARNINGEWB018801. Place the ATV on a level surface.2. Remove panels E and F. (See page 8-9.)3. Place a container und

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

8-29813. Pour the recommended coolant into the radia-tor until it is full.CAUTION:ECB00401● If coolant is not available, use distilled wateror soft ta

8-308NOTE:There is a check hose at the bottom of the air filtercase. If dust or water collects in this hose, emptythe hose and clean the air filter el

8-3184. Pull off the lock plate, and then remove thesponge material from the air filter elementframe.5. Wash the sponge material gently but thor-oughl

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

8-328WARNINGEWB019006. Squeeze the excess solvent out of the spongematerial and let it dry.CAUTION:ECB00440Do not twist the sponge material when squee

8-338will affect carburetor jetting with subsequentpoor performance and possible engine over-heating.EBU23881Cleaning the spark arrester Be sure the e

8-348WARNINGEWB01910EBU23920V-belt cooling duct check hose If dust or water collects in the V-belt cooling ductcheck hose, remove the hose and clean i

8-358EBU23940Adjusting the carburetor The carburetor should be checked and, if neces-sary, adjusted at the intervals specified in the peri-odic mainte

8-3684. Check the engine idling speed and, if neces-sary, adjust it to specification by turning thethrottle stop screw at the carburetor. To in-crease

8-3783. Tighten the locknut.EBU24060Valve clearance The valve clearance changes with use, resulting inimproper air-fuel mixture and/or engine noise. T

8-388NOTE:The wheels need to be removed to check thebrake pads. (See page 8-55.)EBU26460Rear brake padsEach rear brake pad is provided with wear indic

8-398Before riding, check that the brake fluid is abovethe minimum level mark and replenish if neces-sary. A low brake fluid level may indicate wornbr

8-408● Refill with the same type of brake fluid. Mixingfluids may result in a harmful chemical reactionand lead to poor braking performance.● Be caref

8-418EBU27130Adjusting the rear brake lever free play and checking the brake pedal position The brake lever free play must be adjusted andbrake pedal

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

8-4283. Tighten the locknut.If the correct free play cannot be obtained, have aYamaha dealer adjust it.NOTE:When adjusting the rear brake lever free p

8-438EBU24230Axle boots The axle boots must be checked for damage at theintervals specified in the periodic maintenance andlubrication chart. Check th

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

8-458WARNINGEWB02120EBU24911Checking and lubricating the front and rear brake levers The operation of the front and rear brake leversshould be checked

8-468EBU24961Checking the wheel bearings The front and rear wheel bearings must bechecked at the intervals specified in the periodicmaintenance and lu

8-478EBU25080Lubricating the knuckle shafts The knuckle shafts must be lubricated at the inter-vals specified in the periodic maintenance and lu-brica

8-488WARNINGEWB02140To charge the batteryHave a Yamaha dealer charge the battery as soonas possible if it seems to have discharged. Keep inmind that t

8-498CAUTION:ECB00630● Always keep the battery charged. Storing adischarged battery can cause permanentbattery damage.● To charge a sealed-type (MF) b

8-508The main fuse and the fuse box are located underthe seat. (See page 4-14.)If a fuse is blown, replace it as follows.1. Turn the key to “OFF” and

8-518CAUTION:ECB00640To prevent accidental short-circuiting, turn offthe main switch when checking or replacing afuse.2. Remove the blown fuse, and th

2-12EBU17660LOCATION OF THE WARNING AND SPECIFICATION LABELS U1P113E0.book Page 1 Friday, May 19, 2006 9:10 AM

8-5282. Disconnect the headlight coupler by lifting thetab as shown and pulling out the coupler.3. Remove the headlight bulb holder assemblyby turning

8-5384. Install a new headlight bulb holder assemblyby inserting it into the headlight unit and turn-ing it clockwise.CAUTION:ECB00650Do not touch the

8-548To raise a headlight beam, turn the adjustingscrew in direction (a).To lower a headlight beam, turn the adjustingscrew in direction (b).EBU25620R

8-5583. Remove the defective bulb by pushing it inand turning it counterclockwise.4. Insert a new bulb into the bulb holder, push itin, and then turn

8-5682. Elevate the ATV and place a suitable standunder the frame.3. Remove the nuts from the wheel.4. Remove the wheel.EBU25700Installing a wheel 1.

8-5782. Lower the ATV to the ground.3. Tighten the wheel nuts to the specifiedtorques.1. Tapered nutTightening torques:Front wheel nut:55 Nm (5.5 m·kg

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

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

9-29WARNINGEWB02300EBU25932Storage Short-termAlways store your ATV in a cool, dry place and, ifnecessary, protect it against dust with a porouscover.C

9-39b. Pour a teaspoonful of engine oil into thespark plug bore.c. Install the spark plug cap onto the sparkplug, and then place the spark plug on the

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

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

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

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

2-32U1P113E0.book Page 3 Friday, May 19, 2006 9:10 AM

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

11-911EBU26132U1P113E0.book Page 9 Friday, May 19, 2006 9:10 AM

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

2-42U1P113E0.book Page 4 Friday, May 19, 2006 9:10 AM

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

EBU17091U1P113E0.book Page 1 Friday, May 19, 2006 9:10 AM

4-14EBU17720INSTRUMENT AND CONTROL FUNCTIONSWARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.EBU17770Main switc

4-24EBU17812Indicator lights and warning light EBU17830Reverse indicator light “” This indicator light comes on when the transmis-sion is in the rever

4-34EBU17952On-Command four-wheel-drive indicator light “” This indicator light comes on when the On-Com-mand four-wheel-drive switch is set to the “4

4-44NOTE:If the ATV runs out of fuel, move the fuel cock leverto the “RES” position. Approximately 4.5 L (1.19US gal) (0.99 Imp.gal) of fuel will be r

4-54EBU18100Start switch “” Push this switch to crank the engine with the start-er.CAUTION:ECB00050See the starting instructions on page 6-1 priorto s

4-64WARNINGEWB00120EBU18270Throttle lever Once the engine is running, movement of the throt-tle lever will increase the engine speed.Regulate the spee

4-74Before starting the engine, check the throttle to besure it is operating smoothly. Make sure it returnsto the idle position as soon as the lever i

4-843. Tighten the locknut.WARNINGEWB00190EBU18391Front brake lever The front brake lever is located on the right handle-bar. To apply the front brake

4-94EBU18442Brake 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 lefthan

4-104EBU18680Recoil starter Firmly grasp the handle and pull slightly until en-gagement can be felt. Then pull forcefully, beingcareful not to pull th

EBU17170INTRODUCTIONEBU17270Congratulations on your purchase of the Yamaha YFM4FGW. This ATV represents the result of manyyears of Yamaha experience i

4-114EBU18720Fuel tank cap Remove the fuel tank cap by turning it counter-clockwise.EBU18730Fuel Make sure that there is sufficient fuel in the tank.F

4-124CAUTION:ECB00070Use only unleaded gasoline. The use of leadedgasoline will cause severe damage to internalengine parts, such as the valves and pi

4-134OFFWith 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

4-144RESThis indicates reserve. With the fuel cock lever inthis position, the fuel reserve is made available.Turn the fuel cock lever to this position

4-154To 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

4-164CAUTION:ECB00130Do not store metal or sharply edged objects,like tools, in the storage compartment. If theymust be stored, wrap them in appropria

4-174EBU18970Rear 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)

4-184WARNINGEWB00350EBU19180Auxiliary DC jack The auxiliary DC jack is located at the front rightside of the ATV. The auxiliary DC jack can be usedfor

4-1944. 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

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

5-25WARNINGEWB00470Rear brake• Check operation. If soft or spongy, have Yamaha dealer bleed hy-draulic system.• Check lever free play, and adjust if n

5-35WHAT CAN HAPPENIncreases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV each time you use it to

5-45EBU19530Fuel Make sure that there is sufficient fuel in the tank.(See page 4-11.)WARNINGEWB00500EBU19560Engine oil Make sure that the engine oil i

5-55EBU19721Front and rear brakes Brake levers and brake pedal● Check that there is no free play in the front brakelever. If there is free play, have

5-65Brake operationTest the brakes at slow speed after starting out tomake sure they are working properly. If the brakesdo not provide proper braking

5-75EBU19820Measuring the tire pressure Use the low-pressure tire gauge.Rear:Manufacturer/model:MAXXIS/M980Size:AT25 x 10-12Type:Tubeless● The tires s

5-85NOTE:The low-pressure tire gauge is included as stan-dard equipment. Make two measurements of thetire pressure and use the second reading. Dust or

5-95EBU19840Chassis fasteners Make sure that all nuts, bolts and screws are prop-erly tightened.EBU19850Instruments, lights and switches Check that al

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

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

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

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 U1P113E0.book Page 1 Friday, May 19, 2006 9:10 AM

7-27WARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.EBU21411GETTING TO KNOW YOUR ATVThis ATV is for recreation

7-37RIDE WITH CARE AND GOOD JUDGEMENTGet training if you are inexperienced.Beginners should get training from a certified in-structor.Become familiar

7-47WHAT CAN HAPPENUse by children of ATVs that are not recom-mended for their age can lead to severe inju-ry or death of the child.HOW TO AVOID THE H

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

7-57This ATV is designed to carry operator and car-go only – passengers prohibited.WARNINGEWB00910POTENTIAL HAZARDCarrying a passenger on this ATV.WHA

7-67ApparelWARNINGEWB00920POTENTIAL HAZARDOperating this ATV without wearing an ap-proved motorcycle helmet, eye protectionand protective clothing.WHA

7-77Do not operate after consuming alcohol ordrugs.The operator’s performance capability is reducedby the influence of alcohol or drugs.WARNINGEWB0093

7-87WARNINGEWB00950WARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.Do not operate at speeds too fast for your

7-97Speed limiterFor riders less experienced with this model, thethrottle lever housing is equipped with a speed lim-iter. The speed limiter keeps the

7-107WARNINGEWB00970POTENTIAL HAZARDOverloading this ATV or carrying or towingcargo improperly.WHAT CAN HAPPENCould cause changes in ATV handling whic

7-117During operationAlways keep your feet on the footboards during op-eration, otherwise they may contact the rearwheels.WARNINGEWB00980Avoid wheelie

7-127ModificationsWARNINGEWB01000POTENTIAL HAZARDOperating this ATV with improper modifica-tions.WHAT CAN HAPPENImproper installation of accessories o

7-137Exhaust systemThe exhaust system on the ATV is very hot duringand following operation. To prevent burns, avoidtouching the exhaust system. Park t

7-147Do not ride on any public road, street, or highway.Riding on public roads can result in collisions withother vehicles.WARNINGEWB01030HOW TO AVOID

Tires ... 5-6Measuring the tire pressure ... 5-7Tire wear limit ...

7-157Know the terrain where you ride. Ride cautiously inunfamiliar areas. Stay alert for holes, rocks, orroots in the terrain, and other hidden hazard

7-167When 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

7-177Do 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

7-187WARNINGEWB01080As you approach a curve, slow down and begin toturn the handlebars in the desired direction. As youdo so, put your weight on the f

7-197Improper riding procedures such as abrupt throttlechanges, excessive braking, incorrect body move-ments, or too much speed for the sharpness of t

7-207HOW TO AVOID THE HAZARDAlways follow proper procedures for climb-ing hills as described in this Owner’s Manu-al.Always check the terrain carefull

7-217If 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

7-227If you start to roll backwards, DO NOT apply eitherbrake abruptly. If you are in 2WD, apply only thefront brake. If you are in 4WD, because all w

7-237RIDING 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

7-247U1P113E0.book Page 24 Friday, May 19, 2006 9:10 AM

Adjusting the drive select lever safety system cable ... 8-37Checking the front and rear brake pads ... 8-37Ch

7-257CROSSING A SLOPETraversing a sloping surface on your ATV requiresyou to properly position your weight to maintainproper balance. Be sure that you

7-267U1P113E0.book Page 26 Friday, May 19, 2006 9:10 AM

7-277CROSSING 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

7-287CAUTION:ECB00280After riding your ATV in water, be sure to drainthe trapped water by removing the check hoseat the bottom of the air filter case,

7-297RIDING OVER ROUGH TERRAINRiding over rough terrain should be done with cau-tion. Look out for obstacles which could causedamage to the ATV or cou

7-307WHAT CAN HAPPENCould cause loss of control or a collision.Could cause the ATV to overturn.HOW TO AVOID THE HAZARDBefore operating in a new area,

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

7-327WHAT TO DO IF...This section is designed to be a reference guideonly. Be sure to read each section on riding tech-niques completely.WHAT TO DO...

7-337● If your ATV encounters shallow water:Ride slowly and carefully through slow movingwater, watching for obstacles. Be sure to let wa-ter drain fr

8-18EBU21642PERIODIC MAINTENANCE AND MINOR REPAIREBU21660Safety is an obligation of the owner. Periodic in-spection, adjustment and lubrication will k

1-11EBU17430SAFETY INFORMATIONEBU17542AN ATV IS NOT A TOY AND CAN BE HAZARD-OUS TO OPERATE.An ATV handles differently from other vehicles, in-cluding

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

8-38EBU21742Periodic 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

8-58EBU21863General 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

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.U1P113E0.book Page 10 Friday, May 19, 2006 9:10 AM

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