Yamaha YXR66FAV manual

5UG-F8199-12 LIT-11626-19-41 READ THIS MANUAL CAREFULLY! It contains important safety information. YXR66FAV OWNER’S MANUAL[...]

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EVU00010 1- INTRODUCTION Congratulations on your purchase of the Yamaha YXR66FAV. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing vehicles. With the purchase of this Yamaha, you can now appreciate the high degree of crafts- manship and reliability that have made Yamaha[...]

EVU00021 1- IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINE D IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: *Product and specifications are subject to change without notice. The Safety Alert Symbol means ATTENTION! BECOME ALER[...]

AFFIX DEALER LABEL HERE EVU00030 2 - IMPORTANT NOTICE ● This vehicle is designed and manufactured for off-road use only. It is illegal to operate this vehicle on any public street, road, or highway. Such use is prohibited by law. ● Check the laws and regulations in force before choosing where to operate this vehicle. It is illegal to operate th[...]

EVU00050 CONTENTS LOCATION OF THE WAR NING AND SPECIFICATION LABELS ....... 1-1 SAFETY INFORMATION.................. 2-1 DESCRIPTION AND VEH ICLE IDENTIFICATION ............................. 3-1 Identification number records .......... 3-3 Key identification number ..... ........... 3-3 Vehicle identification number .......... 3-4 Model label .....[...]

Seat belts ........................................ 5-7 Steering ............................... ............ 5-8 Fittings and fasteners ...................... 5-8 Lights ............................................... 5-8 Switches .......................................... 5-8 Tires ................................................ 5-8 How to measu[...]

Axle boots ...................................... 8-18 Spark plug inspection .................... 8-20 Cleaning the air filter elements...... 8-22 V-belt cooling duct check hose ..... 8-27 V-belt case drain plug.................... 8-28 Cleaning the spark arrester .. ......... 8-29 Carburetor adjustment................... 8-30 Idle speed adjustment[...]

YAMAHA MOTOR CORPORATION, U.S.A. SIDE × SIDE VEHICLE LIMITED WARRANTY ................... 13-1 YAMAHA EXTENDED SERVICE (Y.E.S.) .......................................... 14-1 13 14 U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM[...]

1-1 EVU00060 1 - LOCATION OF THE WARNING AND SPECIFICATION LABELS U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM[...]

1-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 1 Y AMAHA 5UG-K8483-00 W[...]

1-3 34 W ARNING Y AMAHA 5UG-K7764-00 K eep hands, body , other persons aw ay when closing bed. Do not operate the v ehicle with bed up . Y AMAHA 5UG-F4897-00 W ARNING Se vere INJUR Y or DEA TH can result if you ignore the f ollo wing: Maximum Load in Cargo Bed:181kg. (400lb). Ne ver carry passengers in cargo bed. Cargo can affect handling and stabi[...]

1-4 56 Y AMAHA 5UG-F151J-00 MAX 7.3 INCH (185MM) Y AMAHA 5UG-F151K-02 Improperly loading a trailer and f ailure to use extr a care when pulling trailer can cause an accident or injur y . Nev er load more than 50kg (110 lbs) tongue weight on the towing brac ket. Do not tow more than 550kg (1212 lbs) rolling weight (trailer plus cargo). Operate in lo[...]

1-5 7 8 5UG-F1558-00 T urning the off road vehicle in 4WD-LOCK ( “ DIFF .LOCK ” ) takes more effort. Operate at a slow speed and allo w extr a time and distance for maneuv ers to av oid loss of control. W ARNING AL WA YS USE AN APPRO VED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS OR P AVEMENT NEVER USE WITH DRUGS OR ALCOHOL W ARNING T[...]

2-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SAFETY INFORMATION EVU00070 This off-highway utility vehicle handles differently from other vehicles including cars and ATVs. SEVERE INJURY OR DEATH can result if you do not follow these instructions: ● Read this manual and all labels carefully and follow the operating procedures described. ● This vehicle is[...]

2-2 ● Always inspect your vehicle each time you use it to be sure it is in safe operating condition. Al- ways follow the inspection and maintenance procedures and schedules described in this man- ual. ● Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard. Never hold ont[...]

2-3 ● Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you. Never go over the top of a hill at speed if you cann ot see what is on the other side. ● Always follow proper procedures for going uphill. If you lose momentum and cannot continue up a hill, back down the hil l with the engine in re[...]

2-4 WA R N I N G POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refuel- ing. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling[...]

2-5 WA R N I N G POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation. U5UG12.book Page 5 Thursday, June 23, 2005 9:02 AM[...]

3-1 EVU00080 1 - DESCRIPTION AND VEHICLE IDENTIFICATION 1. Headlights 2. Front shock absorber assembly adjust ing ring 3. Brake fluid reserv oir 4. Air filter element ( engine and air intake duct) 5. V-belt case 6. Driver seat 7. Driver seat belt 8. Spark plug 9. Carg o bed 10. Tail/brake lights 11. Rear shock absorber assembly ad justing ring 12. [...]

3-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 24. Light switch 25. Steering wheel 26. Starter (choke) 27. Main switch 28. On-Command four-whe el drive and differentia l gear lock switches 29. Indicator and warnin g lights 30. Multi-function meter unit (special edition model s) 31. Auxiliary DC j ack 32. Drive select lever 33. Parking brake lever 34. Acceler[...]

3-3 EVU00090 Identification number records Record the key identification number, vehicle identification number and model label infor- mation in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: ACA-02E 2. VEHICLE IDENTIFICATION NUMBER : ACA[...]

3-4 EVU00110 Vehicle identification number The vehicle identification number is stamped into the frame. 1. Vehicle identification number NO TE: _ The vehicle identification number is used to identify your vehicle. _ EVU0012 0 Model label The model label is affixed to the location in the illustration. Record the information on this la- bel in the sp[...]

4-1 EVU00130 1- CONTROL FUNCTIONS EVU00140 Main switch 1. Main switch Functions of the respective switch positions are as follows: ON: All electrical circuits are supplied with power, and the headlights and taillights come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position. START: [...]

4-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CAUTION: _ ● Do not operate the electric starter continuously for more than 5 sec- onds, or starter damage could occur. Wait at least 5 seconds between each operation of the electric starter to let it cool. ● Do not turn the key to the “ START ” position with the engine running, or damage to the electric[...]

4-3 EVU00150 Indicator and warning lights 1. Parking brake indicator light “ P ” 2. Reverse indicator light “ R ” 3. Neutral indicator light “ N ” 4. Four-wheel-drive indicat or light “” 5. Differential gear lock in dicator light “” 6. Coolant temperature warning light “” EVU00210 Parking brake indicator light “ P ” This[...]

4-4 EVU00200 Four-wheel-drive indicator light “” This indicator light comes on when the “ 2WD/ 4WD ” switch is in the “ 4WD ” position. NO TE: _ Due to the synchronizing mechanism in the differential gear case, the light may not come on until the vehicle starts moving. _ EVU00220 Differential gear lock indicator light “” This indica[...]

4-5 EVU00190 Coolant temperature warning light checking method Turn the main switch to “ ON ” . Coolant tem perature warning light does not come o n. Coolant tem perature warning light comes on. Coolant tem perature warning light doe s not come on. Coolant tem perature and electrical circu it are OK. Go ahead with riding. Turn the main switch t[...]

4-6 EVU00150 * Indicator and warning lights (special edition models) 1. 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. Parking brake indicator light “ P ” 7. Four-wheel-drive indi[...]

4-7 EVU00170 Neutral indicator light “ N ” This indicator light comes on when the drive select lever is in the “ N ” position. EVU00160 Reverse indicator light “ R ” This indicator light comes on when the drive select lever is in the “ R ” reverse position. NO TE: _ If the indicator light flashes while riding, have a Yamaha dealer c[...]

4-8 CAUTION: _ ● The engine may overheat if the vehicle is overloaded. If this happens, reduce the load to specification. ● After restarting, make sure that the light is out. Continuous use while the light is on may cause damage to the engine. _ U5UG12.book Page 8 Thursday, June 23, 2005 9:02 AM[...]

4-9 EVU01171* Multi-function meter unit (special edition models) 1. Speedometer 2. “ H ” b utton 3. “ M ” bu tton 4. Clock/Hour meter 5. Odometer/Tripmeter A/Tripmeter B 6. “ TRIP /ODO ” bu tton 7. Clock/Hour button “” / “” The multi-function meter unit is equipped with the following: ● a speedometer (which shows the riding sp[...]

4-10 Odometer and tripmeter modes Pushing the “ TRIP/ODO ” button switches the display between the odometer mode “ ODO ” and the tripmeter modes “ A ” and “ B ” in the fol- lowing order: ODO → TRIP A → TRIP B → ODO To reset a tripmeter, select it by pushing the “ TRIP/ODO ” button, and then push the “ TRIP/ ODO ” butto[...]

4-11 EVU00230 Switches 1. Light switch “ OFF/ / ” EVU00240 Light switch “ OFF/ / ” Set the switch to “” to turn on the low beam and the taillights. Set the switch to “” to turn on the high beam and the taillights. Set the switch to “ OFF ” to turn off all the lights. CAUTION: _ Do not use the headlights with the engine turned of[...]

4-12 EVU01580 On-Command four-wheel drive and differ- ential gear lock switches 1. On-Command four-wheel drive switch “ 2WD ” / “ 4WD ” 2. Differential gear lock switch “ LOCK ” / “ 4WD ” This vehicle is equipped with an On-Com- mand four-wheel drive switch “ 2WD ” / “ 4WD ” and a differential gear lock switch “ LOCK ” /[...]

4-13 On-Command four-wheel drive switch “ 2WD ” / “ 4WD ” 1. Lever 2. On-Command four-whee l drive switch “ 2WD ” / “ 4WD ” To change from 2WD to 4WD, stop the vehi- cle, and then set the switch to “ 4WD ” . When the vehicle is in 4WD, the four-wheel-drive in- dicator light “” or, for special edition models, the four-wheel-d[...]

4-14 Differential gear lock switch “ LOCK ” / “ 4WD ” 1. Differential gear lock switch “ LOCK ” / “ 4WD ” 2. Lever To lock the differential gear in 4WD, stop the vehicle, make sure the On-Command four- wheel-drive switch is set to “ 4WD ” , move the lever to position b , and then set the switch to “ LOCK ” . When the differe[...]

4-15 NO TE: _ ● If the differential gear lock is not engag- ing properly, turn the steering wheel back and forth to help it engage. ● Riding before the differential gear lock is properly engaged will cause the engine speed to be limited until engagement is complete. For special edition models: ● When the switch is set to “ LOCK ” , the di[...]

4-16 Before starting the engine, check the acceler- ator pedal to be sure it is operating smoothly. Make sure the accelerator pedal fully returns to the idle position as soon as it is released. EVU00270 Brake pedal Press the brake pedal to slow or stop the ve- hicle. 1. Brake pedal WA R N I N G POTENTIAL HAZARD Malfunction of the accelerator pedal.[...]

4-17 EVU00280 Parking brake lever The parking brake lever is located at the right side of the driver ’ s seat. It will help hold the vehicle from moving while parked. To set the parking brake, pull the lever up completely. To release the parking brake, pull up on the lever, press the release button, and then push the lever all the way down. Sprin[...]

4-18 EVU00290 Drive select lever The drive select lever is used to shift your ve- hicle into the low, high, neutral and reverse positions. (Refer to pages 6-5 – 6-7 for the drive select lever operation.) 1. Drive select lever EVU0030 0 Fuel tank cap Remove the fuel tank cap by turning it coun- terclockwise. 1. Fuel tank cap U5UG12.book Page 18 Th[...]

4-19 EVU00310 Fuel level check window The amount of fuel in the fuel tank can be checked through the fuel level check window. If the fuel level is low, refuel as soon as possi- ble. 1. Fuel level check window EVU00320 Starter (choke) “” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. [...]

4-20 EVU00330 Seats To remove a seat, pull its seat lock lever up- ward, lift the front of the seat, and then slide the seat forward and up. 1. Driver seat 2. Passenger seat 3. Seat lock lever ( × 2) To install a seat, insert the projections on the rear of the seat into the seat holders and push down on the seat at the front. WA R N I N G POTENTIA[...]

4-21 EVU00340 Seat belts This vehicle is equipped with three-point seat belts for both the operator and passenger. Al- ways wear the seat belt while riding in the ve- hicle. 1. Seat belt ( × 2) 2. Latc h plate ( × 2) 3. Buckle ( × 2) To wear the seat belt properly, do the follow- ing: 1. Hold the latch plate as you pull the belt across your lap [...]

4-22 3. Put the lap portion of the belt low on your hips. Push down on the buckle end of the belt as you pull up on the shoulder part so the belt is snug across your hips. 4. Position the shoulder belt over your shoulder and across your chest. The shoulder belt should fit against your chest. If it is loose, pull the belt out all the way and then le[...]

4-23 EVU01191 Glove compartment CAUTION: _ To protect from damage, do not put metal products, like tools or sharply edged prod- ucts directly in the glove compartment. If they must be stored, wrap them in appro- priate cushion material. _ a. Unlock. b. Open. EVU00351 Cargo bed 1. Cargo bed 2. Tailgate 3. Cargo hook ( × 4) U5UG12.book Page 23 Thurs[...]

4-24 Opening and closing the tailgate 1. Tailgate 2. Latch ( × 2) To open Unhook the latches, and then lower the tail- gate. To close Place the tailgate in the original position, and then hook the latches. Lifting and lowering the cargo bed 1. Cargo bed release lever To lift Push down the cargo bed release lever on the left or right side of the ve[...]

4-25 WA R N I N G POTENTIAL HAZARD Pinch points. WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame when the bed is being lowered. HOW TO AVOID THE HAZARD Before closing the bed, be sure others are standing away from the vehicle. Keep hands and fingers away from the pinch points between the bed and the frame. W[...]

4-26 EVU00360 Front and rear shock absorber adjustment The spring preload can be adjusted to suit the operating conditions. You can reduce preload for a softer ride, or in- crease preload if frequent bottoming occurs. CAUTION: Frequent or severe bottoming can cause increased wear or damage to the vehicle. Adjust the spring preload as follows. To in[...]

4-27 1. Spring preload adjusting ring 2. Position indicator NO TE: _ A special wrench can be obtained at a Yamaha dealer to make this adjustment. _ 1. Special wrench Standard position: B A- Minimum (soft) E- Maximum (hard) U5UG12.book Page 27 Thursday, June 23 , 2005 9:02 AM[...]

4-28 EVU00370 Trailer hitch bracket This vehicle is equipped with a 5 cm (2 in) re- ceiver bracket for a standard trailer hitch. Trailer towing equipment can be obtained at a Yamaha dealer. (See pages 6-11 – 6-1 3 for precaution information.) 1. Trailer hitch bracket WA R N I N G POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPE[...]

4-29 EVU00380 Auxiliary DC jack The auxiliary DC jack is located at the right side of the front panel. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1. Auxiliary DC jack cap 1. Set the light switch to “ OFF ” . 2. Start the engine. (See pages 6-1 ?[...]

4-30 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: _ ● Do not use accessories requiring more than the above maximum capac- ity. This may overload the circuit and cause the fuse to blow. ● If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and e[...]

5-1 EVU01200 1- PRE-OPERATION CHECKS Before using this vehicle, check the following points: ITEM ROUTINE PAGE Brakes • Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. 5-2 – 5-3, 8 -32 – 8-35 Parking brake • Check for proper operatio n, condition and free play. 8-36 – 8-37 Fuel • C[...]

5-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EVU00390 Front and rear brakes Brake pedal Check for correct brake pedal free play. If the brake pedal free play is incorrect, have a Yamaha dealer adjust it. (See page 8-35.) Check the operation of the brake pedal. It should move smoothly and there should be a firm feeling when the brakes are applied. If not, h[...]

5-3 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the bra ke fluid reservoir. Ap- ply the brakes firmly for one minute. If there is any leakage, have the vehicle inspected by a Yamaha dealer. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the bra[...]

5-4 EVU00400 Fuel Make sure there is sufficient gasoline in the tank. CAUTION: _ Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. _ Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane n[...]

5-5 EVU00410 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-9 – 8-12.) CAUTION: _ ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “ CD ” or oils of a high- er quality t[...]

5-6 EVU00420 Coolant Check the coolant level in the coolant reser- voir when the engine is cold. (The coolant lev- el will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum and maximum le vel marks on the coolant reservoir. If the coolant level is at or below the minimum level mark, add additional coolant[...]

5-7 EVU00430 Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-13 – 8-14 for details.) If desired, an SAE 80W90 hypoid gear oil may be used for all conditions. NO TE: _ GL-4 is a quality and additive rating, GL-5 or GL-6 rated hypoid gear oils may also be used. _ EVU00440 Differential gear o[...]

5-8 EVU01230 Steering Park on level ground. Turn the steering wheel right and left. Check for excessive free play, abnormal noises, or a rough feeling. Have a Yamaha dealer repair as necessary for proper operation. EVU00470 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the vehicle to a Yamah[...]

5-9 2. The tires should be set to the rec- ommended pressure: ● Recommended tire pressure Front 70 kPa (0.70 kgf/cm 2 , 10 psi) Rear 98 kPa (0.98 kgf/cm 2 , 14 psi) Check and adjust tire pressures when the tires are cold. Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from[...]

5-10 EVU00510 How to measure tire pressure Use the tire pressure gauge. NO TE: _ The tire pressure gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. _ Set pressure with tires cold. Set tire pressures to the follow[...]

5-11 EVU00520 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit U5UG12.book Page 11 Thursday, June 23 , 2005 9:02 AM[...]

6-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EVU00530 1- OPERATION EVU00540 Starting a cold engine 1. Apply the brake. 2. Shift the drive select lever into the neutral position. WA R N I N G POTENTIAL HAZARD Operating vehicle without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE[...]

6-2 NO TE: _ ● When the drive select lever is in the neu- tral position, the neutral indicator light should come on. If the neutral indicator light does not come on, ask a Yamaha dealer to inspect the electric circuit. ● The engine can be started in any gear if the brake is applied. However, it is rec- ommended to shift into neutral before star[...]

6-3 NO TE: _ If the engine fails to start, release the key, and then try starting again. Wait a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 5 seconds on each attempt. _ 5. If the engine is started with the starter (choke) in position 1 , the starter [...]

6-4 4. Using a charged 12 V battery, connect the positive lead of the jumper cable to the positive terminal of the battery in the vehicle and the other end of the positive lead to the positive terminal of the charged battery. 1. Jumper cable positive lead 2. Jumper cable neg ative lead 5. Connect the negative lead of the jumper cable to the negativ[...]

6-5 EVU00570 Warming up To get maximum engine life, always warm up the engine before starting off. Never acceler- ate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off. EVU00580 Drive select lever operation and reverse driving CAUTION: _ Before shifti[...]

6-6 Shifting: Neutral to Reverse 1. Stop the vehicle. Keep your foot off the accelerator pedal. 2. Apply the brake pedal. 3. Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide. 1. Drive select lever NO TE: _ ● When in reverse, the reverse indicator light should be on. If the light does not come on, [...]

6-7 5. Press the accelerator pedal gradually and continue to watch to the rear while backing. EVU0059 0 Engine break-in There is never a more important period in the life of your vehicle than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not pu[...]

6-8 Each full throttle acceleration sequence should be followed with a substantial rest pe- riod for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer. 0 – 10 hours: Avoid continuous operation above half throt- tle. Allow [...]

6-9 EVU01210 Parking When parking, stop the engine and shift the drive select lever into the neutral position. Ap- ply the parking brake to help prevent the vehi- cle from rolling. EVU00600 Parking on a slope WA R N I N G POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The vehicle could roll out of control, in- creasing the cha[...]

6-10 1. Bring the vehicle to a stop by applying the brakes. 2. Stop the engine. 3. With the brakes applied, set the parking brake. NO TE: Like many other vehicles, the parking brake acts on the rear wheels. For the parking brake to have the effect of braking all four wheels, shift to 4WD before stopping the engine. EVU00610 Accessories and loading [...]

6-11 ● Accessories should be rigidly and securely mounted. An accessory which can shift po- sition or come off while you are operating could affect your ability to control the vehi- cle. ● Do not mount an accessory where it could interfere with your ability to control the vehi- cle. Examples include (but are not limited to) an object that limit[...]

6-12 ● Choose a trailer hitch drawbar designed for use with a 5 cm (2 in) receiver. (See page 4-28 for more information.) ● Do not exceed the maximum tongue weight. You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Adjust the load in the trailer, if necessary,[...]

6-13 WA R N I N G POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle han- dling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed when c[...]

7-1 EVU00640 1 - DRIVING YOUR VEHICLE GETTING TO KNOW YOUR VEHICLE This off-highway utility vehicle will handle and maneuver differently from an ordinary pas- senger car or other vehicle. Before you begin to use your vehicle, be sure you have read this Owner ’ s Manual complete- ly and understand the operation of the con- trols. Pay particular at[...]

7-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 The total weight of operator, passenger, ac- cessories, cargo, trailer tongue weight, and the vehicle itself must not exceed 907 kg (2,000 lb). (See “ Loading ” on page 6-11.) Car- rying a passenger and cargo can affect vehi- cle handling. WA R N I N G POTENTIAL HAZARD Carrying a passenger in the cargo bed. [...]

7-3 The driver and passenger must always wear a seat belt and an approved motorcycle helmet. Also wear eye protection and protective cloth- ing, including over-the-ankle boots, gloves, a long-sleeved shirt or jacket, and long pants. Keep hands and feet inside the vehicle at all times. WA R N I N G POTENTIAL HAZARD Overloading this vehicle or carryi[...]

7-4 WA R N I N G POTENTIAL HAZARD Operating this vehicle without wearing an approved motorcycle helmet, eye protection, and protective clothing. WHAT CAN HAPPEN Operating without an approved motor- cycle helmet in- creases your chances of a severe head injury or death in the event of an ac- cident. Operating without eye protection can re- sult in a[...]

7-5 LEARNING TO OPERATE YOUR VEHICLE You should become familiar with the perfor- mance characteristics of the vehicle in a large, flat area that is free of obstacles and other ve- hicles. Practice control of the accelerator ped- al, brakes, steering, and drive select lever. Drive first at slow speed and become comfort- able at that speed before gra[...]

7-6 CAUTION: _ Do not shift from low to high or vice versa without coming to a complete stop and waiting for the engine to return to normal idle speed. Damage to the engine or drive train may occur. _ TURNING YOUR VEHICLE The vehicle is easier to steer in two-wheel drive (2WD) than four-wheel drive (4WD). Steering takes the most effort in 4WD with [...]

7-7 BRAKING Braking ability is affected by the type of ter- rain. In most cases, gradually application of the brakes is more effective than abrupt brak- ing, particularly on loose surfaces like gravel. Always allow for greater braking distance on rough, loose, or slippery surfaces. GOING UPHILL Do not attempt to climb hills until you have mastered [...]

7-8 Before climbing the hill, first be sure you are operating in low range 4WD or, if necessary, with 4WD Diff. Lock. To climb a hill, you need traction, momentum, and steady throttle. Travel fast enough to keep your momentum going, but not so fast that you cannot react to changes in the terrain as you climb. Slow down when you reach the crest of t[...]

7-9 If you start to lose traction or momentum when climbing, and you decide you will be un- able to continue, use the brakes to come to a stop. Do not attempt to turn the vehicle around. With your foot on the brake, look be- hind you and plan your descent. Shift the drive select lever in reverse so you can use the engine brake if necessary to slow [...]

7-10 Before starting down hill, make sure the vehi- cle is in low-range 4WD. On most slopes, this will let you use engine braking to help you go downhill slowly. Go as slowly as possible. If you are starting to go too fast, apply the brakes gently. Avoid sudden application of the brakes, which could cause the vehicle to start sliding. If you are sl[...]

7-11 CROSSING THROUGH SHALLOW WATER If you must cross shallow, slow moving water up to the depth of the vehicle ’ s floorboards, choose your path carefully to avoid sharp drop-offs, large rocks, or slippery surfaces that could cause the vehicle to overturn. Nev- er operate through water deeper than 33 cm (13 in) or fast flowing water. Wet brakes [...]

7-12 CAUTION: _ After riding your vehicle in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the V-belt case drain plug. Wash the vehi- cle in fresh water if it has been operated in salt water or muddy conditions.[...]

7-13 1. Drive sele ct lever box c heck hose 1. V-belt case drain plug RIDING O VER ROUGH TERRA IN Operating over rough terrain should be done with caution. Look for obstacles that could cause damage to the vehicle or could lead to a rollover or accident. Avoid jumping the vehi- cle as injury, loss of control, and damage to the vehicle could occur. [...]

7-14 RIDING IN BRUSH O R WOODED AREAS When operating in areas with brush or trees, watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit, causing an accident, or for brush that might enter the vehicle as you pass and strike the driver or passenger. Nev- er hold onto the enclosure so your hand [...]

7-15 ENCOUNTERING OBSTAC LES ON THE TRAIL If you cannot go around an obstacle such as a fallen tree trunk or a ditch, stop the vehicle where it is safe to do so. Set the parking brake and get out to inspect the area thoroughly. Look from both your approach side and the exit side. If you believe you can continue safe- ly, decide the path that will a[...]

8-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EVU00650 1- PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment and lubrica- tion will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner. The most im- portant points of vehicle inspection, adjust- ment and lubrication are explained[...]

8-2 1. Owner ’ s tool kit 2. Tire pressure gauge The service information included in this man- ual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor re- pairs. The tools provided in the Owner ’ s tool kit are sufficient for this purpose, except that a torque wrench is [...]

8-3 WA R N I N G POTENTIAL HAZARD Operating this vehicle with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this vehicle through im- proper installation or use of acc[...]

8-4 EVU00671 PERIODIC MAINTENANCE/LUBRICATION NO TE: ● For vehicles not equipped wit h an odometer or hour meter, fo llow the month maintenance intervals. ● For vehicles equipped with an odometer or an hou r meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the vehicle isn ’ t used for a long period of ti[...]

8-5 NO TE: ● Recommended brake f luid: DOT 4 ● Brake fluid replacement: • When disassembling the master cylinder or ca liper, replace the brake fluid. Normally check the brake fluid leve l and add flu- id as required. • On the inner parts of the master cylind er and caliper, replace the oil seals every two years. • Replace the brake hoses[...]

8-6 EVU00680 Hood To open Unhook the hood latches, and then slowly tilt the hood up until it stops. 1. Latch ( × 2) 1. Hood U5UG12.book Page 6 Thursday, June 23, 2005 9:02 AM[...]

8-7 To close Lower the hood slowly to its original position, and then hook the hood latches. Secure projections 1 on the underside of the hood into slots 2 on the back of the instru- ment panel. Secure slots 3 on the side of the hood around projections 4 on the frame. 1. Proj ection ( × 2) 2. Slot ( × 2) 3. Slot ( × 2) 4. Projection ( × 2) CAUT[...]

8-8 EVU00691 Console To remove 1. Remove the seats. (See page 4-20 for seat removal and installation proce- dures.) 2. Remove the parking brake lever boot. 3. Pull the console upward (the drive select lever boot will come loose). 1. Console To install 1. Place the console in its original position. 2. Install the parking brake lever boot. 3. Install[...]

8-9 EVU00700 Engine oil and oil filter cartridge The engine oil level should be checked before each operation. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic mainte- nance and lubrication chart. To check the engine oil level 1. Place the vehicle on a level surface. 2. Remove the[...]

8-10 To change the engine oil (with or without oil filter cartridge replacement) 1. Remove the console. (See page 8-8 for console removal and installation proce- dures.) 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the engine to col- lect the used oil, and then remove the en- gine oil filler c[...]

8-11 6. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. NO TE: _ Make sure the O-ring is seated properly. _ 1. O-ring 7. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 1. Oil filter cartridge 2. Torque wrench 8. Install the engine oil [...]

8-12 CAUTION: _ ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “ CD ” or oils of a high- er quality than specified. In addition, do not use oils labeled “ ENERG Y CONSERVING II ” or higher. ● Make sure that no fore[...]

8-13 EVU00710 Final gear oil Checking the final gear oil level 1. Place the vehicle on a level surface. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. 1. Final gear oil filler bolt 2. Final gear oil 3. Correct oil level NO TE: _ The oil level should be at the brim of the filler hole. _ 3. If the oil is below the[...]

8-14 Changing the final gear oil 1. Place the vehicle on a level surface. 2. Place a container under the final gear case to collect the used oil. 3. Remove the oil filler bolt and the drain bolt to drain the oil. 1. Final gear oil drain bolt 4. Install the drain bolt, and then tighten it to the specified torque. 5. Add the recommended final gear oi[...]

8-15 EVU00721 Differential gear oil Checking the differential gear oil level 1. Place the vehicle on a level surface. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to the brim of the filler hole. If the level is low, add sufficient oil of the recommend- ed type to raise it to the specified level. 1. Differ[...]

8-16 1. Differential gear oil drain bolt 4. Install the differential gear oil drain bolt, and tighten it to the specified torque. 5. Fill the differential gear case with the rec- ommended oil. CAUTION: _ Be sure no foreign material enters the dif- ferential gear case. _ 6. Install the differential gear oil filler bolt, and then tighten it to the sp[...]

8-17 EVU00730 Coolant The coolant level should be checked before each ride. Checking the coolant level 1. Place the vehicle on a level surface. 2. Open the hood. (See pages 8-6 – 8-7 for hood opening and closing procedures.) 3. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level varies with engine tempera[...]

8-18 CAUTION: _ Mix anti freeze with distilled water only. However, if distilled water is not available, soft water may be used for refilling. _ Changing the coolant The coolant must be changed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. N O TE: _ ● Adding water instead of coolant lowers the an[...]

8-19 1. Rear axle boot ( × 2 each side) U5UG12.book Page 19 Thursday, June 23 , 2005 9:02 AM[...]

8-20 EVU00750 Spark plug inspection Removal 1. Lift the cargo bed up. (See pages 4-23 – 4-26 for cargo bed lifting and lowering procedures.) 2. Remove the spark plug cap. 1. Spark plug cap 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown. 1. Spark plug wrench U5UG12.book Page 20 Thursday, June 23 , 2005 9:02 AM[...]

8-21 Inspection The spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color of the porcelain insulator around the center electrode is a medium-to- light tan for a vehicle that is being ridden nor- mally. Do not attempt to diagnose such problems y[...]

8-22 3. Install the spark plug and tighten it to the specified torque. NO TE: _ If a torque wrench is not available when you are installing the spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past fin- ger tight. Have the spark plug tightened to the specified torque as soon as possible. _ 4. Install the spark plug cap. 5. Lower[...]

8-23 2. Remove the air filter element from the air intake duct grill by pulling it out as shown. 1. Air filter element 2. Air intake duct grill 3. Remove any large particles from the air filter element by hand. 4. Tap the air filter element to remove most of the dust and dirt, and then blow the re- maining dirt out with compressed air. 1. Air filte[...]

8-24 Cleaning the engine air filter element NO TE: _ There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. _ 1. Air filter case check hose 1. Remove the seats. (See page 4-20 for seat removal and installation proce- dures.) 2. Remove t[...]

8-25 1. Air filter element 1. Air filter frame 2. Air filter element 3. Element retaining plate 6. Wash the air filter element gently but thoroughly in solvent. 7. Squeeze the excess solvent out of the air filter element and let it dry. CAUTION: _ Do not twist the air filter element when squeezing it. _ 8. Inspect the air filter element and replace[...]

8-26 9. Thoroughly apply Yamaha foam air filter oil or other quality liquid foam air filter oil (not spray type) to the air filter element. NO TE: _ The air filter element should be wet but not dripping. _ 10. Pull the air filter element over its frame. 11. Install the air filter element. 12. Install the air filter case cover and be sure the crankc[...]

8-27 CAUTION: _ Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, op- eration without the air filter element will af- fect carburetor jetting with subsequent poor performance and possible engine overheating. EVU0077 0 V-belt cool[...]

8-28 EVU00780 V-belt case drain plug The V-belt case drain plug is located under the driver seat. (See page 4-20 for seat re- moval and installation procedures.) After riding in water deep enough to allow wa- ter to enter the V-belt case, remove the drain plug to drain any water from the case. NO TE: _ If water drains from the V-belt case after re-[...]

8-29 EVU00792 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 1. Bolt ( × 3) 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon depos- its from the spark arrester portion of the tailpi[...]

8-30 EVU00800 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and ex- perience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine. CAUTION: _ The[...]

8-31 EVU00810 Idle speed adjustment NO TE: _ A diagnostic tachometer must be used for this procedure. _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Remove the seats. (See page 4-20 for [...]

8-32 EVU00830 Front brake pad check Each brake pad is provided with wear indica- tor grooves, which allow you to check the brake pad wear without having to disassem- ble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indica- tor grooves have almost disappeared, have a Yam[...]

8-33 EVU00840 Rear brake pad check Each brake pad is provided with wear indica- tor grooves, which allow you to check the brake pad wear without having to disassem- ble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indica- tor grooves have almost disappeared, have a Yama[...]

8-34 The brake fluid reservoir is located under the hood. (See pages 8-6 – 8-7 for hood opening and closing procedures.) Observe these precautions: ● When checking the fluid level, make sure the top of the brake fluid reservoir is level. ● Use only the recommended quality brake fluid. Otherwise, the rubber seals may de- teriorate, causing lea[...]

8-35 EVU01220 Checking the brake pedal Have a Yamaha dealer check the brakes at the intervals specified in the periodic mainte- nance and lubrication chart. There should be no free play in the brake pedal. The brakes should operate smoothly and there should be no brake drag. If the brakes feel soft or spongy, this could indicate air in the brake sy[...]

8-36 EVU00870 Parking brake lever free play adjustment Periodically check the parking brake lever free play and adjust it if necessary. 1. Shift the drive select lever into low gear “ L ” . 2. Remove the seats. (See page 4-20 for seat removal and installation proce- dures.) 3. Remove the console. (See page 8-8 for console removal and installati[...]

8-37 1. Locknut 2. Adjusting nut 6. Turn the adjusting nut in direction a to increase the free play or in direction b to decrease the free play. 7. Tighten the locknut. 8. Install the console. 9. Install the seats. EVU0088 0 Brake light switch adjustment The brake light switch, which is activated by the brake pedal, is properly adjusted when the br[...]

8-38 1. Brake light switch 2. Adjusting nut 3. Close the hood. EVU00890 Cable inspection and lubrication Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. WA R N I N G POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of cont[...]

8-39 EVU00900 Brake pedal and accelerator pedal lubrication Lubricate the pivoting parts. EVU0091 0 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Recommended lubricant: Lithium-soap-based grease U5UG12.book Page 39 [...]

8-40 EVU00920 Steering shaft lubrication Lubricate the pivot points. EVU00930 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the vehicle and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. 1. Nut ( × 4) Recommended lubricant: Lithium-soap-based grease (all purpose grease) U5UG12.book Page 40 Thur[...]

8-41 EVU00940 Wheel installation 1. Install the wheel and the nuts. NO TE: _ ● The arrow mark on the tire must point toward the rotating direction of the wheel. ● Tapered nuts are used for both the front and rear wheels. Install the nut with its ta- pered side towards the wheel. _ 1. Arrow mark 1. Tapered nut 2. Lower the vehicle so that the wh[...]

8-42 EVU00950 Battery This vehicle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the bat- tery. If the battery seems to have discharged, consult a Yamaha dealer. CAUTION: _ Do not try to remove the sealing caps of the battery cells. You may damage the bat- tery. _ WA R N I N[...]

8-43 EVU00960 Battery maintenance 1. When the vehicle is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely re- charge the battery before reinstallation. CAUTION: _ A special battery charger (constant volt- age/ampere or constant voltage) is re- quired for recharging a sealed-type battery. Using a conv[...]

8-44 EVU00970 Fuse replacement The main fuse and the fuse box are located under the hood. (See pages 8-6 – 8-7 for hood opening and closing procedures.) If a fuse is blown, turn off the main switch and install a new fuse of the specified amperage. If a fuse is blown, replace it as follows. 1. Remove the battery compartment cover by lifting it up [...]

8-45 4. Turn the key to “ ON ” and turn on the electrical circuit in question to check if the device operates. 5. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 6. Install the battery compartment cover. 7. Close the hood. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Ignition fuse: 10.0 A Auxi[...]

8-46 EVU00981 Replacing a headlight bulb If a headlight bulb burns out, replace it as fol- lows. 1. Lift the hood up. (See pages 8-6 – 8-7 for hood opening and closing procedures.) 2. Remove the bulb holder cover at the rear of the headlight by pulling it off. 1. Headlight bulb holder cover 3. Disconnect the headlight coupler by lift- ing the tab[...]

8-47 4. Remove the headlight bulb holder as- sembly by turning it counterclockwise. 1. Headlight bulb holde r assembly NO TE: _ The headlight bulb cannot be removed from the headlight bulb holder. To replace the headlight bulb, replace the headlight bulb holder assembly. _ 5. Install a new headlight bulb holder as- sembly by inserting it and turnin[...]

8-48 1. Do not touch the glass part of the bulb. CAUTION: _ Do not touch the glass part of the head- light bulb to keep it free from o il, otherwise the transparency of the glass, the luminos- ity of the bulb, and the bulb life will be ad- versely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened[...]

8-49 EVU00990 Headlight beam adjustment CAUTION: _ It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction a . To lower the beam, turn the adjusting screw in direction b . 1. Headlight beam adjusting screw U5UG12.book Page 49 Thursday, June 23 , 2005 9:02 AM[...]

8-50 EVU01000 Tail/brake light bulb replacement If a tail/brake light bu lb burns out, replace it as follows: 1. Remove panel A (if replacing the left tail/ brake bulb) or panel B (if replacing the right tail/brake bulb) by removing the quick fasteners and bolts. 1. Panel A 1. Panel B 1. Quick fastener ( × 8) 2. Bolt ( × 2) 3. Panel A U5UG12.book[...]

8-51 2. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 1. Tail/brake light bulb holder 3. Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder. 4. Push a new bulb in and turn it clockwise to install in the bulb holder. 5. Install the bulb holder (together with the bulb) by turnin[...]

8-52 EVU01010 Troubleshooting Although Yamaha vehicles receive a rigid in- spection before shipment from the factory, trouble may occur during operation. Any prob- lem in the fuel, compression, or ignition sys- tems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your vehi[...]

8-53 EVU01020 Troubleshooting charts Starting problems or poor engine performance 1. Fuel Check if there is fuel in the fuel tank. There is fuel. No fuel. Fuel pump is clogged. Restart the engine. No fuel. Supply fuel. 2. Compression Use the electric starter to see if there is compression. There is compression. Compression normal. No compression. A[...]

8-54 Engine overheating NO TE: _ If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible. _ WA R N I N G POTENTIAL HAZARD Removing the radiator cap when the en- gine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid an[...]

9-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EVU01030 1- CLEANING AND STORAGE A. CLEANING Frequent, thorough cleaning of your vehicle will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the vehicle: a. Block off the end of the exhaust pipe to prevent water entry. A [...]

9-2 6. Clean the seats with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may scratch the paint or protective finish. When finished, start the engine and let it idle for several minutes. W[...]

9-3 EVU01040 B. STORAGE Long term storage (60 days or more) of your vehicle will require some preventive proce- dures to guard against deterioration. After thoroughly cleaning the vehicle, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or equivalent produc[...]

9-4 8. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an ex- cessively warm or cold place (less than 0 ° C (30 ° F) or more than 30 ° C (90 ° F)). NO TE: _ Make any necessary repairs before storing the vehicle. _ U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM[...]

10-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EVU01050 1- SPECIFICATIONS Model YXR66F A V Dimensions: Ov erall length 2,885 mm (113.6 in) Ov erall width 1,385 mm (54.5 in) Ov erall height 1,853 mm (73.0 in) Seat height 818 mm (32.2 in) Wheelbase 1,910 mm (75.2 in) Ground clearance 280 mm (11.02 in) Minimum tur ning radius 3,900 mm (153 .5 in) Basic weight:[...]

10-2 Engine oil: Type 10 ° 30 ° 50 ° 70 ° 90 ° 110 ° 0 ° 130 ° F -10 ° 0 ° 10 ° 20 ° 30 ° 40 ° -20 ° 50 ° C YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 Recommended engine oil classification API Service SE, SF, SG type or higher Quantity: Without oil filter cartridge replacement 1.90 L (1.67 Imp qt, 2.01 [...]

10-3 Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity: 0.25 L (0.22 Imp qt, 0.26 US qt) Differential gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity: 0.32 L (0.28 Imp qt, 0.34 US qt) Radiator capacity (includin g all routes): 2.50 L (2.20 Imp qt, 2.64 US qt) Air filter : Engine W et element Intake duct Dr y element Fuel[...]

10-4 T ransmission: Primar y redu ction system V -belt Secondar y reduction system Shaft drive Secondar y reduction ratio 41/21 × 24/18 × 33/9 (9.54 4) T ransmission type V -belt automatic Operation Right hand operation Re verse gear 25/17 (1.471) Sub transmission ratio low 35/17 (2.058 ) high 28/19 (1.473) Chassis: F rame type Steel tube frame C[...]

10-5 Brak es: System F ront and rear unified T ype front Dual disc brake rear Single di sc brak e Operation Foot operation Suspension: F ront suspension Double wishbone Rear suspension Doub le wishbone Shock absorber: F ront shock absorber Coil spri ng/oil damper Rear shock absorber Coil spring/oil damper Wheel trav el: F ront wheel tra vel 185.0 m[...]

10-6 Bulb voltage , wattage × quantity: Headlight 12 V 30 W/30.0 W × 2 T ail/bra ke lig ht 12 V 5 W/21.0 W × 2 Indicator lights: Neutral indicator light 12 V 1.7 W × 1 LED (speci al edition model s) Re verse indicator light 12 V 1.7 W × 1 LED (speci al edition model s) Coolant temperature warning light 12 V 1.7 W × 1 LED (speci al edition mod[...]

10-7 Specified fuses: Main fuse 30.0 A Headlight fuse 15.0 A Ignition fu se 10.0 A A uxiliar y DC jack fuse 10.0 A F our-wheel-dr iv e fuse 3.0 A Carb uretor w armer fuse 10.0 A Signaling system fuse 10.0 A Back up fuse 10.0 A Model YXR66F A V U5UG12.book Page 7 Thursday, June 23, 2005 9:02 AM[...]

11-1 EVU01060 1 - NOISE REGULATION TAMPERING WITH NOISE CONTROL SYS TEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice or element of design incorporated into any new vehicle for the pu[...]

12-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EVU01070 1 - MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and insta ll will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work is required. It is not acceptable proof of m[...]

13-1 EVU01081 YAMAHA MOTOR CORPORATION, U.S. A. SIDE × SIDE VEHICLE L IMITED WARRANTY Y amaha Motor Corporation, U.S .A. hereby warrants that new Y amaha Side × Side vehicles purchased from an authorized Y amaha Side × Side V ehicle dealer in the continental United States will be free from defects in material and workmanship for the period of ti[...]

14-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EVU01090 YAMAHA EXTENDED SER VICE (Y.E.S.) U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM[...]

14-2 U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM[...]

PRINTED IN USA 2005.07-4.8 × 1 CR (E) Y AMAHA MO T OR CO. , L TD .[...]