ATV/SxS Service Data 1995~2009 - Welcome to Maul … Manuals/YAMAHA/ATV-SxS...2008 ATV/SxS Technical...

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©2009 Yamaha Motor Corporation, U.S.A.Printed in U.S.A.

ATV/SxSService Data1995~2009

LIT-SDATA-AT-00

ATVGeneral Information

1995~2009 ATVData Sheet Reference

Data Sheet Reference - Page 1

Mo

del

Mar

ket

Nam

eM

od

el

Co

de

1995

(G)

1996

(H)

1997 (J)

199

(K)

1999

(L)

200

0

(M)

2001

(N)

2002

(P)

2003

(R)

2004

(S)

2005

(T)

2006

(V)

2007

(W)

2008

(X)

2009

(Y)

YF

M50

Rap

tor

50(5

YF

)

YF

M80

Bad

ger

(4E

M)

YF

M80

GG

rizzl

y 80

(2D

3)

YF

M80

WR

apto

r 80

(5T

H)

YF

M90

RR

apto

r 90

(43D

)

YFA

1B

reez

e(3

FA)

YF

M12

5GG

rizzl

y 12

5(1

C5)

YF

S20

0B

last

er(5

VM

)

YF

B25

0T

imbe

rwol

f 2W

D(4

BD

)

YF

B25

0FT

imbe

rwol

f 4W

D(4

KD

)

YF

M25

BB

ruin

250

/

Big

Bea

r 25

0(1

P0)

YF

M25

XB

earT

rack

er(4

XE

)

YF

M35

BA

Bru

in 2

WD

(5W

H)

YF

M35

FAB

ruin

4W

D(5

UH

)

YF

M35

FG

Griz

zly

350

4WD

(5U

H)

YF

M35

FG

IG

rizzl

y 35

0

4WD

IR

S(4

S2)

YF

M35

GG

rizzl

y 35

0 2W

D(5

WH

)

YF

M35

XW

olve

rine

350

(3D

5)

YF

M35

0ER

Mot

o-4

(3H

P)

YF

M35

0FW

Big

Bea

r 4W

D(3

HN

)

YF

M35

0FW

BB

ig B

ear

4WD

(5F

T)

YF

M35

0FW

JB

ig B

ear

SE

4W

D(4

WU

)

1995~2009 ATVData Sheet Reference (Continued)


Mo

del

Mar

ket

Nam

eM

od

el

Co

de

1995

(G)

1996

(H)

1997 (J)

199

(K)

1999

(L)

200

0

(M)

2001

(N)

2002

(P)

2003

(R)

2004

(S)

2005

(T)

2006

(V)

2007

(W)

2008

(X)

2009

(Y)

YF

M35

FX

Wol

verin

e 4W

D(4

KB

) (2

D4)

YF

M35

0R

Rap

tor

350

(5Y

T)

YF

M35

0UB

ig B

ear

2WD

(5F

E)

YF

M35

0XW

arrio

r(5

NF

)

YF

Z35

0B

ansh

ee(5

FK

)

YF

M4A

Kod

iak

2WD

(5V

H)

YF

M4F

AK

odia

k 4W

D(5

TE

))

YF

M4F

AK

odia

k 4W

D(1

P1)

YF

M40

Big

Bea

r 2W

D(5

GW

)

YF

M40

FB

ig B

ear

4WD

(5F

U)

YF

M40

FB

Big

Bea

r 40

0 4W

D I

RS

(4S

1)

YF

M40

0AK

odia

k 2W

D(5

HA

)

YF

M40

0FK

odia

k 4W

D(4

GB

)

YF

M40

0FK

odia

k 4W

D(4

SH

)

YF

M40

0FK

odia

k 4W

D(5

EH

)

YF

M40

0FA

Kod

iak

4WD

(5G

H)

YF

M45

FAK

odia

k 45

0 4W

D(5

ND

)

YF

M45

FAK

odia

k 45

0 4W

D /

Griz

zly

450

4WD

(1D

9)

YF

M45

FG

Griz

zly

450

4WD

(17S

) (3

7S)

YF

M45

FX

Wol

verin

e 45

0 4W

D(3

C2)

1995~2009 ATVData Sheet Reference (Continued)


Mo

del

Mar

ket

Nam

eM

od

el

Co

de

1995

(G)

1996

(H)

1997 (J)

199

(K)

1999

(L)

200

0

(M)

2001

(N)

2002

(P)

2003

(R)

2004

(S)

2005

(T)

2006

(V)

2007

(W)

2008

(X)

2009

(Y)

YF

Z45

0Y

FZ

450

(5T

G)

YF

Z45

0Y

FZ

450

(5TG

) (5

D3)

YF

Z45

0RY

FZ

450R

(18P

)

YF

M5F

G /

PG

rizzl

y 55

0 /

550

EP

S(2

8P)

(34D

)

YF

M60

0FA

Griz

zly

4WD

(4W

V)

YF

M60

0FA

Griz

zly

4WD

(5G

T)

YF

M66

0FG

rizzl

y 66

0 4W

D(5

KM

) (2

C6)

(2

3D)

YF

M66

0R66

0R R

apto

r (5

LP)

YF

M7F

G /

PG

rizzl

y 70

0 /

700

EP

S

(5C

0)(3

B4)

(4

3P)

YF

M70

RR

apto

r 70

0R(1

S3)

ATV 6/10/2009 AT2009-009

SUBJECTS: 1. All Ultramatic Models – V-Belt Information

©2009 YAMAHA MOTOR CORPORATION, U.S.A.

All Ultramatic Models – V-Belt InformationThe following information has been provided to better assist you when servicing the V-belt of an Ultra-matic ATV. The following V-belt chart is also available in the new Spec Data book.

Part NumberModel

ApplicationTop Width

“A” mm“A” Wear Limit mm

Thickness “B” mm

Angle “C” Degree

Outside Circumference

mm

28P-17641-00-00 YFM550F (28P, 34D) 32.7 30.0 15.8 + 0.6 27 + 1 944 + 3

3B4-17641-00-00 YFM700F (3B4, 43P, 5C0)

31.7 30.0 15.8 + 0.6 27 + 1 944 + 3

5KM-17641-01-00 YFM660F (5KM, 2C6, 23D) 32.7 30.0 14.9 + 0.6 26 + 1 944 + 3

5UH-17641-01-00 YFM350F (5UH, 4S2)YFM350A (5WH, 3D5)

28.0 26.2 13.3 + 0.6 27 + 1 854 + 3

5GH-17641-10-00 YFM400F (5GH, 5TE, 5VH, 1P1)YFM450F (1D9, 17S, 5ND)

28.3 27.3 13.6 + 0.6 28 + 1 876 + 3

3C2-17641-00-00 YFM450FA (3C2) 28.3 27.3 13.6 + 0.6 28 + 1 876 + 3

4WV-17641-01-00 YFM600F (4WV, 5GT) 31.7 30.0 13.8 + 0.6 26 + 1 944 + 3

NOTE: Although some V-belts share common dimensions, they cannot be interchanged because the construction material is specific to the application.

For easy Model Code cross reference, use the Starting PID Number reference pages listed in the Spec Data book.

ATV 5/23/08 AT2008-003

2008 MODELSATV Service Literature

PAGE 1 of 3


This bulletin contains a comprehensive listing of Service Literature Part Numbers for 2008 models. Certain models will not have new literature if the prior year’s information is still current. The manuals listed in the chart below can be ordered from Crestec Los Angeles, Inc. (Ph: 1-888-530-9446, FAX: 1-310-527-5835). This bulletin also lists other publications related to your dealership operation (see page 3), which can be ordered from Yamaha Parts and Accessories.

YFM50RX Raptor 50 LIT-11626-21-38 YFM50WS N/A N/A YFM50WS LIT-11616-17-13 LIT-11666-17-13

YFM80GX Grizzly 80 LIT-11626-21-06 YFM80WD N/A N/A YFM80GT LIT-11616-GZ-80 LIT-11666-18-47 YFM80GHX Grizzly 80 LIT-11626-21-06 YFM80WD N/A N/A YFM80GT

Hunter LIT-11616-GZ-80 LIT-11666-18-47

YFM80RX Raptor 80 LIT-11626-21-23 YFM80WD N/A N/A YFM80WP LIT-11616-YF-81 LIT-11666-15-38

YFM125GX Grizzly 125 LIT-11626-21-05 YFM125W N/A N/A YFM125S LIT-11616-GZ-12 LIT-11666-17-56 YFM125GHX Grizzly 125 LIT-11626-21-05 YFM125W N/A N/A YFM125S Hunter LIT-11616-GZ-12 LIT-11666-17-56

YFM25BX Big Bear 250 LIT-11626-21-16 YFM25BT N/A N/A YFM250XL LIT-11616-BT-26 LIT-11666-12-01

YFM25RX Raptor 250 LIT-11626-21-39 LIT-11616-21-22 N/A N/A LIT-11666-21-22

YFM25RSPX Raptor 250 SE LIT-11626-21-39 LIT-11616-21-22 N/A N/A LIT-11666-21-22

YFM25RSP2X Raptor 250 SE II LIT-11626-21-39 LIT-11616-21-22 N/A N/A LIT-11666-21-22 YFM35GX Grizzly 350 2WD LIT-11626-21-19 YFM400FAR N/A N/A YFM35AS LIT-11616-BN-20 LIT-11616-17-33 YFM35FGX Grizzly 350 4WD LIT-11626-21-17 YFM400FAR N/A N/A YFM35FAS LIT-11616-BN-35 LIT-11666-17-32

YFM35FGIX Grizzly 350 IRS LIT-11626-21-40 YFM35FGIW N/A N/A YFM35FGIW 4WD LIT-11616-20-46 LIT-11666-20-46 YFM35FGIHX Grizzly 350 IRS LIT-11626-21-40 YFM35FGIHW N/A N/A YFM35FGIHW 4WD Hunter LIT-11616-20-46 LIT-11666-20-46

YFM35FGHX Grizzly 350 4WD LIT-11626-21-17 YFM400FAR N/A N/A YFM35FAS Hunter LIT-11616-BN-35 LIT-11666-17-32 YFM35RX Raptor 350 LIT-11626-21-10 YFM350XA N/A N/A YFM350S LIT-11616-RP-35 LIT-11666-17-57

YFM35XX Wolverine 350 LIT-11626-21-18 YFM400R N/A N/A YFM35XV 2WD LIT-11616-FX-20 LIT-11666-19-80

New ’08 Model Owner’s Service Manual ’08 Supplements Compilation Manual Assembly Model Name Manual (Main) (Supplements Only) (Main & Supplements) Manual

PAGE 2 of 3

YFM40FBX Big Bear 400 4WD LIT-11626-21-20 YFM40FBW N/A N/A YFM40FBW LIT-11616-20-45 LIT-1666-20-45

YFM40FBHX Big Bear 400 4WD LIT-11626-21-20 YFM40FBHW N/A N/A YFM40FBHW Hunter LIT-11616-20-45 LIT-1666-20-45

YFM4FGX Grizzly 400 4WD LIT-11626-21-45 YFM400FAR LIT-11616-21-45 LIT-11616-KK-41 YFM400FAR LIT-11616-KK-40 LIT-11666-18-36

YFM4FGHX Grizzly 400 4WD LIT-11626-21-45 YFM400FAR LIT-11616-21-45 LIT-11616-KK-41 YFM400FAR Hunter LIT-11616-KK-40 LIT-11666-18-36

YFM45FGX Grizzly 450 4WD LIT-11626-21-64 YFM450FAR LIT-11616-21-46 LIT-11616-KD-47 LIT-11666-21-46

LIT-11616-KD-46

YFM45FGSPX Grizzly 450 SE LIT-11626-21-64 YFM450FAR LIT-11616-21-46 LIT-11616-KD-47 LIT-11666-21-46

LIT-11616-KD-46

YFM45FGHX Grizzly 450 LIT-11626-21-64 YFM450FAR LIT-11616-21-46 LIT-11616-KD-47 LIT-11666-21-46 Hunter LIT-11616-KD-46

YFM45FXX Wolverine 450 4WD LIT-11626-21-47 YFM450FAR N/A N/A YFM45FXV

LIT11616-FX-45 LIT-11666-19-42

YFMFXSPX Wolverine 450 4WD LIT-11626-21-47 YFM450FAR N/A N/A YFM45FXV Sport SE LIT11616-FX-45 LIT-11666-19-42

YFZ450X YFZ450 LIT-11626-21-11 YFZ450S N/A N/A YFZ450S LIT-11616-YF-46 LIT-11666-19-32 YFZ450SPX YFZ450 SE LIT-11626-21-11 YFZ450S N/A N/A YFZ450S LIT-11616-YF-46 LIT-11666-19-32

YFZ450SP2X YFZ450 SE II LIT-11626-21-11 YFZ450S N/A N/A YFZ450S (Black Flames) LIT-11616-YF-46 LIT-11666-19-32

YFM66FGX Grizzly 660 LIT-11626-21-03 YFM660FP N/A N/A YFM660FP LIT-11616-GZ-66 LIT-11666-15-01

YFM66FGHX Grizzly 660 LIT-11626-21-03 YFM660FP N/A N/A YFM660FP Hunter LIT-11616-GZ-66 LIT-11666-15-01

YFM70RX Raptor 700 LIT-11626-21-04 YFM70RV N/A N/A YFM70RV LIT-11616-RP-70 LIT-11666-19-13

YFM70RSPX Raptor 700 SE LIT-11626-21-12 YFM70RV N/A N/A YFM70RV LIT-11616-RP-70 LIT-11666-19-13

YFM70RSP2X Raptor 700 SE II LIT-11626-21-12 YFM70RV N/A N/A YFM70RV LIT-11616-RP-70 LIT-11666-19-13

YFM7FGX Grizzly 700 FI 4WD LIT-11626-21-01 YFM7FGPW LIT-11616-21-02 LIT-11616-GZ-70 YFM7FGPW

LIT-11616-20-11 LIT-11666-20-11

YFM7FGPX Grizzly 700 FI LIT-11626-21-01 YFM7FGPW LIT-11616-21-02 LIT-11616-GZ-70 YFM7FGPW EPS 4WD LIT-11616-20-11 LIT-11666-20-11

YFM7FGHX Grizzly 700 FI LIT-11626-21-01 YFM7FGPHW LIT-11616-21-02 LIT-11616-GZ-70 YFM7FGPHW Hunter LIT-11616-20-11 LIT-11666-20-11

YFM7FGPHX Grizzly 700 FI EPS LIT-11626-21-02 YFM7FGPHW LIT-11616-21-02 LIT-11616-GZ-70 YFM7FGPHW Hunter LIT-11616-20-11 LIT-11666-20-11

YFM7FGPSPX Grizzly 700 FI SE LIT-11626-21-02 YFM7FGPSEW LIT-11616-21-02 LIT-11616-GZ-70 YFM7FGPSEW LIT-11616-20-11 LIT-11666-20-11

YFM7FGPDUX Grizzly 700 FI EPS LIT-11626-21-02 YFM7FGPDUW LIT-11616-21-02 LIT-11616-GZ-70 YFM7FGPDUW Ducks Unlimited LIT-11616-20-11 LIT-11666-20-11


2008 ATV Service Literature

ROUTE TO: SERVICE PARTS WARRANTY SALES! ! ! !

CATEGORY PUBLICATIONS PART NUMBER

2008 Utility ATV Accessory Catalog LIT-ATCAT-UT-08 2008 Off Road & Sport ATV Accessory Catalog LIT-10080-YS-08 2008 ATV Full Line Mini Brochure LIT-ATVMI-N1-08 2008 Sport ATV Brochure LIT-11108-SP-RT 2008 Utility ATV Brochure LIT-11108-UT-IL Tips and Practice Guide for the ATV Rider LIT-11626-15-48 Ride Smart, Ride Safe DVD VID-17299-00-00 2006 & Later ATV Limited Warranty Statement LIT-11790-62-06 ATV Safety Alert LIT-17451-02-06 Used ATV Safety Verification Form LIT-17299-01-2K Y-12 Hang Tag (YFM80 models only) 4EM-2819R-00-00 Y-6 Hang Tag (YFM50 models only) 5YF-2819R-00-00 Utility Hang Tag 5KM-2819R-00-00 Sport Hang Tag 5LP-2819R-00-00 General Hang Tag (all others) 5KM-2819R-00-00 ATV Set-Up and Predelivery Checklist LIT-17161-00-07 2008 ATV/SxS Technical Update Book LIT-17500-AT-08 2007 ATV Service Manual CD LIT-CDSRV-AT-07 Parts System Handbook LIT-10080-07-04 ATV Drop-off Inspection Form LIT-INSPC-FM-AT Warranty Labor Rate Change Request LIT-11791-02-02 ’95 ~ ’05 ATV Service Data Book LIT-SDATA-AT-00 2008 ATV Flat Rate Manual LIT-17750-00-08 Warranty and Y.E.S. Handbook LIT-11760-00-05 Service Schedule Pad LIT-11561-00-96 Heavy Duty Service Binder LIT-10501-01-80 Y.E.S. Plan Highlights - Motorsports LIT-11580-00-05 Y.E.S. Motorsports Sample Contract LIT-11580-00-38 Y.E.S. Registration Card LIT-11580-00-04 Y.E.S. Used Unit Registration Card LIT-11580-00-19 Y.E.S. Motorsports Used Hang Tag LIT-11580-00-40 Y.E.S. Motorsports Hang Tag LIT-11580-00-16 Y.E.S. Motorsports Brochure LIT-11580-00-36 Y.E.S. Maintenance Log LIT-11580-00-03 Y.E.S. Request to Cancel Form LIT-11580-00-10 Y.E.S. Plan Lienholder Information LIT-11580-00-08 Y.E.S. It Works Video DVD-10660-00-04 Y.E.S. Motorsports Poster LIT-11580-00-41

OTHER PUBLICATIONS Order the following publications from Yamaha Parts and Accessories:

Consumer

General Service and Warranty

Yamaha Extended Service (Y.E.S.)

Model Year Suffi x Letter Chart

Model Year Model Year

1998 K

1999 L

2000 M

2001 N

2002 P

2003 R

2004 S

2005 T

2006 V

2007 W

2008 X



1988 U

1989 W

1990 A

1991 B

1992 D

1993 E

1994 F

1995 G

1996 H

1997 J

PAGE 3 of 3


YFM50RX Raptor 50 49cc 5YFD AA023-0000002 YFM80GX Grizzly 80 79cc 2D3A AB04Y-0000002 YFM80RX Raptor 80 79cc 5THL AB05Y-0000002 YFM125GX Grizzly 125 124cc 1C5H AE03Y-0000002 YFM125GHX Grizzly 125 Hunter (Realtree® AP HD™ Camo) 124cc 1C5L AE03Y-0000002 YFM25BX Big Bear 250 230cc 1P0D AG05Y-0000101 YFM25RX Raptor 250 249cc 4D31 AG04Y-0000032 YFM25RSPX Raptor 250 Special Edition Black/Orange 249cc 4D35 AG04Y-0000032 YFM25RSP2X Raptor 250 Special Edition 2 Black 249cc 4D39 AG04Y-0000032 YFM35RX Raptor 350 348cc 5YTS AH31Y-0000101 YFM35RSPX Raptor 350 Special Edition Black 348cc 5YT AH31Y-0000101 YFM35GX Grizzly 350 2WD 348cc 5WHD AH28Y-0002009 YFM35FGX Grizzly 350 4WD 348cc 5UHL AH30Y-0000102 YFM35FGHX Grizzly 350 4WD Hunter (Realtree® AP HD™ Camo) 348cc 5UHR AH25Y-0000101 YFM35FGIX Grizzly 350 IRS 4WD 348cc 4S26 AH23Y-0000101 YFM35FGIHX Grizzly 350 IRS 4WD Hunter (Realtree® AP HD™ Camo) 348cc 4S2A AH24Y-0000101 YFM35XX Wolverine 350 2WD 348cc 3D56 AH31Y-0000101 YFM40FBX Big Bear 400 4WD 386cc 4S15 AH29Y-0002000 YFM40FBHX Big Bear 400 4WD Hunter (Realtree® AP HD™ Camo) 386cc 4S18 AH26Y-0000101 YFM4FGX Grizzly 400 4WD 401cc 1P1D AJ28Y-0014301 YFM4FGHX Grizzly 400 4WD Hunter (Realtree® AP HD™ Camo) 401cc 1P1G AJ29Y-0000101 YFM45FGX Grizzly 450 4WD 421cc 17S1 AJ26Y-0000101 YFM45FGHX Grizzly 4WD Hunter (Realtree® AP HD™ Camo) 421cc 17S5 AJ27Y-0010501 YFM45FGSPX Grizzly 450 4WD Special Edition 421cc 17SA AJ36Y-0000101 YFM45FXX Wolverine 450 4WD 421cc 3C2A AJ31Y-0000101 YFM45FXSPX Woverine 450 4WD Special Edition 421cc 3C2D AJ33Y-0000101 YFZ450X YFZ450 449cc 5D3B AJ35Y-0000004 YFZ450SPX YFZ450 Special Edition White/Blue 449cc 5D3E AJ35Y-0000004 YFZ450SP2X YFZ450 Special Edition 2 Black/Orange 449cc 5D3J AJ35Y-0000004 YFM66FGX Grizzly 660 4WD 660cc 23D1 AM12Y-0000001 YFM66FGHX Grizzly 660 4WD Hunter (Realtree® AP HD™ Camo) 660cc 23D5 AM12Y-0000001 YFM7FGX Grizzly 700 FI 4WD 686cc 5C01 AM15Y-0000005

ATV 1/14/08 AT2008-001

2008 MODELSATV Primary ID Numbers

PAGE 1 of 2


The following is a comprehensive listing of Primary ID numbers for 2008 Yamaha ATVs. The frame number of a unit contains the Primary ID for warranty purposes. Production started with the listed numbers below. For more Primary ID details, see Technical Bulletin AT97-006 or AT99-003. The Model Code appears on a label on the ATV and is useful to help identify the model when contacting Yamaha Parts & Accessories. This code is also referenced with other model information at the beginning of the Parts List on CD-ROM.

Model Model Name Displacement Model Code Starting PID No.

YFM7FGHX Grizzly 700 FI 4WD Hunter (Realtree® AP HD™ Camo) 686cc 5C05 AM15Y-0000005 YFM7FGPX Grizzly 700 FI 4WD EPS 686cc 3B49 AM13Y-0000009 YFM7FGPHX Grizzly 700 FI 4WD EPS Hunter (Realtree® AP HD™ Camo) 686cc 3B4H AM13Y-0000009 YFM7FGPSPX Grizzly 700 FI 4WD EPS Special Edition 686cc 3B4M AM13Y-0000009 YFM7FGPDUX Grizzly 700 FI 4WD EPS Ducks Unlimited® Edition 686cc 3B4L AM13Y-0000009 YFM70RX Raptor 700 686cc 1S3H AM14Y-0000004 YFM70RSPX Raptor 700 Special Edition Red/White 686cc 1S3M AM14Y-0000004 YFM70RSP2X Raptor 700 Special Edition Black w/Flames 686cc 1S3S AM14Y-0000004


PAGE 2 of 2

2008 ATV Primary ID Numbers

ATV 4/19/07 AT2007-004


PAGE 1 of 3



YFM50RW Raptor 50 LIT-11626-20-27 YFM50WS N/A N/A YFM50WS LIT-11616-17-13 LIT-11666-17-13

YFM80GW Grizzly 80 LIT-11626-20-06 YFM80WD N/A N/A YFM80GT LIT-11616-GZ-80 LIT-11666-18-47 YFM80GHW Grizzly 80 LIT-11626-20-06 YFM80WD N/A N/A YFM80GT

Hunter LIT-11616-GZ-80 LIT-11666-18-47

YFM80RW Raptor 80 LIT-11626-20-14 YFM80WD N/A N/A YFM80WP LIT-11616-YF-81 LIT-11666-15-38

YFM125GW Grizzly 125 LIT-11626-20-07 YFM125W N/A N/A YFM125S LIT-11616-GZ-12 LIT-11666-17-56

YFM125GHW Grizzly 125 LIT-11626-20-07 YFM125W N/A N/A YFM125S Hunter LIT-11616-GZ-12 LIT-11666-17-56

YFM25BW Big Bear 250 LIT-11626-20-16 YFM25BT N/A N/A YFM250XL LIT-11616-BT-26 LIT-11666-12-01

YFM35GW Grizzly 350 2WD LIT-11626-20-19 YFM400FAR N/A N/A YFM35AS LIT-11616-BN-20 LIT-11616-17-33 YFM35FGW Grizzly 350 4WD LIT-11626-20-18 YFM400FAR N/A N/A YFM35FAS LIT-11616-BN-35 LIT-11666-17-32

YFM35FGIW Grizzly 350 IRS LIT-11626-20-46 LIT-11616-20-46 N/A N/A LIT-11666-20-46

YFM35FGIHW Grizzly 350 IRS LIT-11626-20-46 LIT-11616-20-46 N/A N/A LIT-11666-20-46 Hunter

YFM35RW Raptor 350 LIT-11626-20-10 YFM350XA N/A N/A YFM350S LIT-11616-RP-35 LIT-11666-17-57

YFM350RSEW Raptor 350 SE LIT-11626-20-10 YFM350XA N/A N/A YFM350S LIT-11616-RP-35 LIT-11666-17-57

YFM350RSE2W Raptor 350 LIT-11626-20-10 YFM350XA N/A N/A YFM350S Special Edition 2 LIT-11616-RP-35 LIT-11666-17-57

YFM35XW Wolverine 350 LIT-11626-20-39 YFM400R N/A N/A YFM35X 2WD Sport LIT-11616-FX-20 LIT-1666-19-80


PAGE 2 of 3

YFM40FBW Big Bear 400 IRS LIT-11626-20-45 LIT-11616-20-45 N/A N/A LIT-1666-20-45

YFM40FBHW Big Bear 400 IRS LIT-11626-20-45 LIT-11616-20-45 N/A N/A LIT-1666-20-45 Hunter

YFM40FBEW Big Bear 400 IRS LIT-11626-20-45 LIT-11616-20-45 N/A N/A LIT-1666-20-45 Exploring Edition

YFM4FGW Grizzly 400 LIT-11626-20-33 YFM400FAR N/A N/A YFM400FAR LIT-11616-KK-40 LIT-11666-18-36

YFM4FGHW Grizzly 400 4WD LIT-11626-20-33 YFM400FAR N/A N/A YFM400FAR Hunter LIT-11616-KK-40 LIT-11666-18-36

YFM45FGW Grizzly 450 LIT-11626-20-17 YFM450FAR N/A N/A YFM450FAR LIT-11616-KD-46 LIT-11666-16-01

YFM45FGOHW Grizzly 450 4WD LIT-11626-20-17 YFM450FAR N/A N/A YFM450FAR Outdoorsman LIT-11616-KD-46 LIT-11666-16-01 Edition

YFM45FGHW Grizzly 450 LIT-11626-20-17 YFM450FAR N/A N/A YFM450FAR Hunter LIT-11616-KD-46 LIT-11666-16-01

YFM45FGSEW Grizzly 450 LIT-11626-20-17 YFM450FAR N/A N/A YFM450FAR Sport Special Edition LIT-11616-KD-46 LIT-11666-16-01

YFM45FXW Wolverine 450 4x4 LIT-11626-20-38 YFM450FAR N/A N/A YFM45FXV

Sport LIT11616-FX-45 LIT-11666-19-42

YFMFXSEW Wolverine 450 4x4 LIT-11626-20-38 YFM450FAR N/A N/A YFM45FXV Sport SE LIT11616-FX-45 LIT-11666-19-42

YFZ450W YFZ450 LIT-11626-20-13 YFZ450S LIT-11616-20-13 LIT-11616-YF-46 YFZ450S LIT-11616-YF-45 LIT-11666-19-32

YFZ450BBW YFZ450 LIT-11626-20-44 YFZ450S LIT-11616-20-13

LIT-11616-YF-46 YFZ450S Bill Ballance Edition LIT-11616-YF-45 LIT-11666-19-32

YFZ450SEW YFZ450 Special Edition LIT-11626-20-44 YFZ450S LIT-11616-20-13

LIT-11616-YF-46 YFZ450S LIT-11616-YF-45 LIT-11666-19-32

YFZ450SEW YFZ450 Special Edition 2 LIT-11626-20-44 YFZ450S LIT-11616-20-13 LIT-11616-YF-46 YFZ450S (Black Flames) LIT-11616-YF-45 LIT-11666-19-32

YFM66FGW Grizzly 660 LIT-11626-20-05 YFM660FP N/A N/A YFM660FP LIT-11616-GZ-66 LIT-11666-15-01

YFM66FGHW Grizzly 660 LIT-11626-20-05 YFM660FP N/A N/A YFM660FP Hunter LIT-11616-GZ-66 LIT-11666-15-01

YFM70RW Raptor 700 LIT-11626-20-12 YFM70RV LIT-11616-20-12 LIT-11616-RP-70 YFM70RV LIT-11616-19-13 LIT-11666-19-13

YFM700RSEW Raptor 700 LIT-11626-20-34 YFM70RV LIT-11616-20-12

LIT-11616-RP-70 YFM70RV Special Edition LIT-11616-19-13 LIT-11666-19-13

YFM70RSE2W Raptor 700 LIT-11626-20-34 YFM70RV LIT-11616-20-12 LIT-11616-RP-70 YFM70RV Special Edition 2 LIT-11616-19-13 LIT-11666-19-13

YFM70RYRW Raptor 700 LIT-11626-20-34 YFM70RV LIT-11616-20-12 LIT-11616-RP-70 YFM70RV GYTR Edition LIT-11616-19-13 LIT-11666-19-13

YFM7FGPW Grizzly 700 LIT-11626-20-63 LIT-11616-20-11 N/A N/A LIT-11666-20-11

YFM7FGPOHW Grizzly 700 LIT-11626-20-63 LIT-11616-20-11 N/A N/A LIT-11666-20-11 Outdoorsman Edition

YFM7FGPHW Grizzly 700 LIT-11626-20-63 LIT-11616-20-11 N/A N/A LIT-11666-20-11 Hunter

YFM45FGPSEW Grizzly 700 LIT-11626-20-63 LIT-11616-20-11 N/A N/A LIT-11666-20-11 Special Edition

YFM7FGPDUW Grizzly 700 LIT-11626-20-63 LIT-11616-20-11 N/A N/A LIT-11666-20-11 Ducks Unlimited Edition



ROUTE TO: SERVICE PARTS WARRANTY SALES✓ ✓ ✓ ✓

CATEGORY PUBLICATIONS PART NUMBER 2007 Utility ATV & Rhino Accessories and Apparel Catalog LIT-ATCAT-UT-07 2007 Sport ATV Accessories and Apparel Catalog LIT-ATCAT-SP-06 2007 ATV Full Line Mini Brochure LIT-ATVMI-N1-07 2007 Sport ATVs Brochure LIT-11107-SP-RT 2007 Utility ATVs Brochure LIT-11107-UT-IL Tips and Practice Guide for the ATV Rider LIT-11626-15-48 Ride Safe, Ride Smart DVD VID-17299-00-00 2006~ ATV Warranty Statement LIT-11790-62-06 ATV Safety Alert LIT-17451-02-06 Used ATV Safety Verification Form LIT-17299-01-2K Y-12 Hang Tag (YFM80 models only) 4EM-2819R-00-00 Y-6 Hang Tag (YFM50 models only) 5YF-2819R-00-00 Utility Hang Tag 5KM-2819R-00-00 Sport Hang Tag 5LP-2819R-00-00 General Hang Tag (all others) 5KM-2819R-00-00 ATV Set-Up and Predelivery Checklist LIT-17161-00-06 2001 ~ 2005 Technical Update DVD LIT-175MT-R5-DV 2007 ATV/SxS Technical Update Book LIT-17500-AT-07 ’85 ~ ’94 ATV Service Manual DVD LIT-CDSRV-AT-85 ’95 ~ ’04 ATV Service Manuals CD LIT-CDSRV-AT-10 2005 ATV Service Manual CD LIT-CDSRV-AT-05 2006-ATV Service Manual CD LIT-CDSRV-AT-06 Parts System Handbook LIT-10080-07-04 Warranty Labor Rate Change Request LIT-11791-02-02 ’95 ~ ’05 ATV Service Data Book LIT-SDATA-AT-00 2006 ATV Flat Rate Manual LIT-17750-00-06 Warranty and Y.E.S. Handbook LIT-11760-00-05 Service Schedule Pad LIT-11561-00-96 Heavy Duty Service Binder LIT-10501-01-80 Y.E.S. Plan Highlights - Motorsports LIT-11580-00-05 Y.E.S. Motorsports Sample Contract LIT-11580-00-38 Y.E.S. Registration Card LIT-11580-00-04 Y.E.S. Used Unit Registration Card LIT-11580-00-19 Y.E.S. Motorsports Used Hang Tag LIT-11580-00-40 Y.E.S. Motorsports Hang Tag LIT-11580-00-16 Y.E.S. Motorsports Brochure LIT-11580-00-36 Y.E.S. Maintenance Log LIT-11580-00-03 Y.E.S. Request to Cancel Form LIT-11580-00-10 Y.E.S. Plan Lienholder Information LIT-11580-00-08 Y.E.S. It Works Video DVD-10660-00-04 Y.E.S. Motorsports Poster LIT-11580-00-41


Consumer





1988 U

1989 W

1990 A

1991 B

1992 D

1993 E

1994 F

1995 G

1996 H

1997 J



1998 K

1999 L

2000 M

2001 N

2002 P

2003 R

2004 S

2005 T

2006 V

2007 W

PAGE 3 of 3


YFM50RW Raptor 50 49cc 5YF AA013-0020207

YFM80GW Grizzly 80 79cc 2D3 AB03Y-0009116

YFM80GHW Grizzly 80 Hunter (Hardwoods® HD Camo) 79cc 2D3 AB03Y-0009116

YFM80RW Raptor 80 79cc 5TH AB02Y-0047320

YFM125GW Grizzly 125 124cc 1C5 AE02Y-0014078

YFM125GHW Grizzly 125 Hunter (Hardwoods® HD Camo) 124cc 1C5 AE02Y-0014078

YFM25BW Big Bear 250 230cc 1P0 AG01Y-0126702

YFM350RW Raptor 350 348cc 5YT AH12Y-0033634

YFM350RSEW Raptor 350 Special Edition Black 348cc 5YT AH12Y-0033634

YFM35RSE2W Raptor 350 Special Edition White/Blue 348cc 5YT AH12Y-0033634

YFM35GW Grizzly 350 2WD 348cc 5WH AH10Y-0023001

YFM35FGW Grizzly 350 4WD 348cc 5UH AH09Y-0034219

YFM35FGIW Grizzly 350 IRS 4WD 348cc 4S2 AH15Y-0000101

YFM35FGIHW Grizzly 350 IRS 4WD Hunter (Hardwoods® HD Camo) 348cc 4S2 AH17Y-0000101

YFM35XW Wolverine 350 2WD 348cc 3D5 AH14Y-0001801

YFM40FBW Big Bear 400 4WD 386cc 4S1 AH16Y-0000101

YFM40FBHW Big Bear 400 4WD Hunter (Hardwoods® HD Camo) 386cc 4S1 AH20Y-0000101

YFM40FBEW Big Bear 400 4WD Exploring Edition 386cc 4S1 AH16Y-0000101

YFM40GW Grizzly 400 4WD 401cc 1P1 AJ15Y-0014301

YFM40GHW Grizzly 400 4WD Hunter (Hardwoods® HD Camo) 401cc 1P1 AJ17Y-0003301

YFM45FGW Grizzly 450 4WD 421cc 1D9 AJ14Y-0026535

YFM45FGHW Grizzly 4WD Hunter (Hardwoods® HD Camo) 421cc 1D9 AJ16Y-0010501

YFM45FGOHW Grizzly 450 4WD Outdoorsman Edition 421cc 1D9 AJ16Y-0010501

YFM45FGSEW Grizzly 450 4WD Special Edition 421cc 1D9 AJ18Y-0004601

YFM45FXW Wolverine 450 4WD 421cc 3C2 AJ21Y-0006501

YFM45FXSEW Woverine 450 4WD Special Edition 421cc 3C2 AJ23Y-0000101

YFZ450W YFZ450 449cc 5D3 AJ20Y-0021141

YFZ450BBW YFZ450 Bill Ballance Edition w/Kit 449cc 5D3 AJ20Y-0021141

YFZ450SEW YFZ450 Special Edition White w/ Red Flames 449cc 5D3 AJ20Y-0021141

YFZ450SE2W YFZ450 Special Edition Black w/ Carbon Flames 449cc 5D3 AJ20Y-0021141

YFM66FGW Grizzly 660 4WD 660cc 2C6 AM03Y-0102894

YFM66FGHW Grizzly 660 4WD Hunter (Hardwoods® HD Camo) 660cc 2C6 AM03Y-0102894

ATV 3/16/07 AT2007-001


PAGE 1 of 2




YFM7FGPW Grizzly 700 4WD 686cc 3B4 AM09Y-0000018

YFM7FGPHW Grizzly 700 4WD Hunter (Hardwoods® HD Camo) 686cc 3B4 AM09Y-0000018

YFM7FGPSEW Grizzly 700 4WD Special Edition 686cc 3B4 AM09Y-0000018

YFM7FGPOHW Grizzly 700 4WD Outdoorsman Edition 686cc 3B4 AM09Y-0000018

YFM7FGPDUW Grizzly 700 4WD Ducks Unlimited® Edition 686cc 3B4 AM09Y-0000018

YFM70RW Raptor 700R 686cc 1S3 AM07Y-0026549

YFM70RSEW Raptor 700R Special Edition Orange/Black 686cc 1S3 AM07Y-0026549

YFM70RSE2W Raptor 700R Special Edition White/Blue 686cc 1S3 AM07Y-0026549

YFM70RYRW Raptor 700R GYTR™ Edition 686cc 1S3 AM07Y-0026549


PAGE 2 of 2


ATV 7/13/06 AT2006-003


PAGE 1 of 4

©2006 YAMAHA MOTOR CORPORATION, USA


YFM50RV Raptor 50 LIT-11626-19-67 YFM50WS YFM50WS LIT-11616-17-13 LIT-11666-17-13 YFM80GV Grizzly 80 LIT-11626-19-61 YFM80WD LIT-11616-18-47 LIT-11616-GZ-80 YFM80GT LIT-11616-YF-80 LIT-11666-18-47 YFM80GHV Grizzly 80 LIT-11626-19-61 YFM80WD LIT-11616-18-47 LIT-11616-GZ-80 YFM80GT Hunter LIT-11616-YF-80 LIT-11666-18-47 Hardwoods® HD Camo YFM80RV Raptor 80 LIT-11626-19-64 YFM80WD YFM80WP LIT-11616-YF-81 LIT-11666-15-38

YFM125GV Grizzly 125 LIT-11626-19-05 YFM125W YFM125S LIT-11616-GZ-12 LIT-11666-17-56 YFM125GHV Grizzly 125 LIT-11626-19-05 YFM125W YFM125S Hunter LIT-11616-GZ-12 LIT-11666-17-56 Hardwoods® HD Camo YFS200V Blaster LIT-11626-19-14 YFS200U YFS200S LIT-11616-BL-20 LIT-11666-17-07 YFS200SEV Blaster SE LIT-11626-19-15 YFS200U YFS200S LIT-11616-BL-20 LIT-11666-17-07

YFM25BV Bruin 250 2WD LIT-11626-19-40 YFM25BT YFM250XL LIT-11616-BT-26 LIT-11666-12-01

YFM35BAV Bruin 350 2WD LIT-11626-19-66 YFM400FAR YFM35AS LIT-11616-BN-20 LIT-11616-17-33 YFM35FAV Bruin 350 4WD LIT-11626-19-65 YFM400FAR YFM35FAS LIT-11616-BN-35 LIT-11666-17-32 YFM35FAHV Bruin 350 4WD LIT-11626-19-65 YFM400FAR YFM35FAHS Hunter LIT-11616-BN-35 LIT-11666-17-32 Hardwoods® HD Camo YFM35XV Wolverine 350 LIT-11626-19-80 YFM400FAR LIT-11616-19-80 LIT-11616-FX-20 LIT-1666-19-80 2WD LIT-11616-BN-20

New Model Owner’s Service Manual Supplements Compilation Manual Assembly Model Name Manual (Main) (Supplements Only) (Main & Supplements) Manual

PAGE 2 of 4

YFM350RV Raptor 350 LIT-11626-19-68 YFM350XA YFM350S LIT-11616-RP-35 LIT-11666-17-57 YFM350RSEV Raptor 350 SE LIT-11626-19-68 YFM350XA YFM350S LIT-11616-RP-35 LIT-11666-17-57

YFZ350V Banshee LIT-11626-19-15 YFZ350T YFZ350S LIT-11616-YF-37 LIT-11666- 17-04

YFZ350SEV Banshee SE LIT-11626-19-15 YFZ350T YFZ350LES LIT-11616-YF-37 LIT-11666- 17-04

YFZ350SPV Banshee SP LIT-11626-19-15 YFZ350T YFZ350LES 50th Anniv. Ed. LIT-11616-YF-37 LIT-11666- 17-04

YFM40FV Big Bear 400 4WD LIT-11626-19-62 YFM400FM YFM40FWNM LIT-11616-BB-40 LIT-11666-13-22

YFM4FAV Kodiak 400 4WD LIT-11626-19-58 YFM400FAR YFM400FAR LIT-11616-KK-40 LIT-11666-18-36 YFM4FAHV Kodiak 400 4WD LIT-11626-19-58 YFM400FAR YFM400FAR Hunter LIT-11616-KK-40 LIT-11666-18-36 Hardwoods® HD Camo

YFM45FAV Kodiak 450 4WD LIT-11626-19-57 YFM450FAR YFM450FAR LIT-11616-KD-46 LIT-11666-16-01

YFM45FABGGV Kodiak 450 LIT-11626-19-57 YFM450FAR YFM450FAR Outdoorsman LIT-11616-KD-46 LIT-11666-16-01 Edition Hunter Green

YFM45FABGHV Kodiak 450 LIT-11626-19-57 YFM450FAR YFM450FAR Outdoorsman LIT-11616-KD-46 LIT-11666-16-01 Edition Hunter Hardwoods® HD Camo

YFM45FAHV Kodiak 450 4WD LIT-11626-19-57 YFM450FAR YFM450FAR Hunter LIT-11616-KD-46 LIT-11666-16-01 Hardwoods® HD Camo

YFM45FASEV Kodiak 450 4WD LIT-11626-19-57 YFM450FAR YFM450FAR SE LIT-11616-KD-46 LIT-11666-16-01

YFM45FXV Wolverine 450 4WD LIT-11626-19-42 LIT-11616-16-01 LIT-11616-19-42 LIT-11616-FX-45 LIT-11666-19-42

YFZ450V YFZ450 LIT-11626-19-77 YFZ450S LIT-11616-19-32 LIT-11616-YF-45 LIT-11666-19-32 LIT-11616-17-11

YFZ450BBV YFZ450 LIT-11626-19-63 YFZ450S LIT-11616-19-32 LIT-11616-YF-45 LIT-11666-19-32 Bill Ballance Edition LIT-11616-17-11

YFZ450SPV YFZ450 SP LIT-11626-19-77 YFZ450S LIT-11616-19-32 LIT-11616-YF-45 LIT-11666-19-32 50th Anniv. Edition LIT-11616-17-11

YFM66FAV Grizzly 660 LIT-11626-19-60 YFM660FP YFM660FP LIT-11616-GZ-66 LIT-11666-15-01

YFM66FAHV Grizzly 660 LIT-11626-19-60 YFM660FP YFM660FP Hunter LIT-11616-GZ-66 LIT-11666-15-01 Hardwoods® HD Camo YFM66FABGGV Grizzly 660 4WD LIT-11626-19-60 YFM660FP YFM660FP Outdoorsman Ed. LIT-11616-GZ-66 LIT-11666-15-01 Hunter Green



PAGE 3 of 4

CATEGORY PUBLICATIONS PART NUMBER 2006 ATV Utility Accessory Brochure LIT-ATCAT-UT-06 2006 Sport ATV Accessory Brochurre LIT-ATCAT-SP-06 2006 ATV Full Line Mini Brochure LIT-ATVMI-N1-06 2006 Sports ATVs Brochure LIT-11106-SP-RT 2006 Utility ATVs Brochure LIT-11106-UT-IL Tips and Practice Guide for the ATV Rider LIT-11626-15-48 Ride Safe, Ride Smart Videotape VID-17299-00-00 ATV Rally CD-ROM LIT-17299-CD-00 2006~ ATV Warranty Statement* LIT-11790-62-06 ATV Safety Alert LIT-17451-02-05 Used ATV Safety Verification Form LIT-17299-01-2K Y-12 Hang Tag (YFM80 models only) 4EM-2819R-00-00 Y-6 Hang Tag (YFM50 models only) 5YF-2819R-00-00 Utility Hang Tag 5KM-2819R-00-00 Sport Hang Tag (660R Raptor, Banshee, Warrior, Blaster) 5LP-2819R-00-00 General Hang Tag (all others) 5KM-2819R-00-00 ATV Set-Up and Predelivery Checklist LIT-17161-00-05 2006 MCY/ATV/SxS Technical Update Book LIT-17500-00-06 ’95 ~ ’04 ATV Service Manuals CD LIT-CDSRV-AT-10 2005 ATV Service Manual CD LIT-CDSRV-AT-05 2006-ATV Service Manual CD LIT-CDSRV-AT-06 Parts System Handbook LIT-10080-07-04 Warranty Labor Rate Change Request LIT-11791-02-02 ’95 ~ ’05 ATV Service Data Book LIT-SDATA-AT-00 2005 ATV Flat Rate Manual LIT-17750-00-05 Warranty and Y.E.S. Handbook LIT-11760-00-04 Service Schedule Pad LIT-11561-00-96 Heavy Duty Service Binder LIT-10501-01-80 Y.E.S. Plan Highlights - Motorsports LIT-11580-00-05 Y.E.S. Motorsports Sample Contract LIT-11580-00-38 Y.E.S. Registration Card LIT-11580-00-04 Y.E.S. Used Unit Registration Card LIT-11580-00-19 Y.E.S. Motorsports Used Hang Tag LIT-11580-00-40 Y.E.S. Motorsports Hang Tag LIT-11580-00-16 Y.E.S. Motorsports Brochure LIT-11580-00-36 Y.E.S. Maintenance Log LIT-11580-00-03 Y.E.S. Request to Cancel Form LIT-11580-00-10 Y.E.S. Plan Lienholder Information LIT-11580-00-08 Y.E.S. It Works Video DVD-10660-00-04 Y.E.S. Motorsports Poster LIT-11580-00-41


Consumer



YFM66FABGHV Grizzly 660 4WD LIT-11626-19-60 YFM660FP YFM660FP Outdoorsman Ed. LIT-11616-GZ-66 LIT-11666-15-01 Hunter Hardwoods HD Camo

YFM66FASEV Grizzly 660 SE LIT-11626-19-60 YFM660FP YFM660FP LIT-11616-GZ-66 LIT-11666-15-01

YFM66FAHDV Grizzly 660 LIT-11626-19-60 YFM660FP YFM660FP Ducks Unlimited® LIT-11616-GZ-66 LIT-11666-15-01

YFM700RV Raptor 700 LIT-11626-19-59 LIT-11616-19-13 LIT-11666-19-13

YFM700RSPV Raptor 700 SP LIT-11626-19-59 LIT-11616-19-13 LIT-11666-19-13 50th Anniv. Ed.






1988 U

1989 W

1990 A

1991 B

1992 D

1993 E

1994 F

1995 G

1996 H

1997 J

1998 K

1999 L

2000 M

2001 N

2002 P

2003 R

2004 S

2005 T

2006 V

PAGE 4 of 4


YFM50RV Raptor 50 49cc 5YF AA013-0014769

YFM80GV Grizzly 80 79cc 2D3 AB03Y-0005505

YFM80GHV Grizzly 80 Hunter (Hardwoods® HD Camo) 79cc 2D3 AB03Y-0005505

YFM80RV Raptor 80 79cc 5TH AB02Y-0040147

YFM125GV Grizzly 125 124cc 1C5 AE02Y-0009067

YFM125GHV Grizzly 125 Hunter (Hardwoods® HD Camo) 124cc 1C5 AE02Y-0009067

YFS200V Blaster 195cc 5VM AG023-0034951

YFS200SEV Blaster SE 195cc 5VM AG023-0034951

YFM25BV Bruin 250 2WD 230cc 1P0 AG01Y-0120901

YFM350RV Raptor 350 348cc 5YT AH12Y-0020670

YFM350RSEV Raptor 350 SE 348cc 5YT AH12Y-0020670

YFM35BAV Bruin 350 Auto 2WD 348cc 5WH AH10Y-0016601

YFM35FAV Bruin 350 Auto 4WD 348cc 5UH AH09Y-0023501

YFM35FAHV Bruin 350 Auto 4WD Hunter (Hardwoods® HD Camo) 348cc 5UH AH13Y-0003601

YFM35XV Wolverine 350 2WD 348cc 3D5 AH14Y-0000101

YFZ350V Banshee 347cc 3B5 3GG03-0063868

YFZ350SEV Banshee SE 347cc 3B5 3GG03-0063868

YFZ350SPV Banshee SP 50th Anniversary Edition 347cc 3B5 3GG03-0063868

YFM40FV Big Bear 400 4WD 386cc 5FU AH06Y-0057601

YFM4FAV Kodiak 400 4WD 401cc 1P1 AJ15Y-0009601

YFM4FAHV Kodiak 400 4WD Hunter (Hardwoods® HD Camo) 401cc 1P1 AJ17Y-0002101

YFM45FABGGV Kodiak 450 Outdoorsman Edition w/Kit 421cc 1D9 AJ16Y-0005301 Hunter Green

YFM45FASEV Kodiak 450 4WD Special Edition 421cc 1D9 AJ18Y-0000101

YFM45FABGHV Kodiak 450 Outdoorsman Edition w/Kit 421cc 1D9 AJ16Y-0005301 (Hardwoods® HD Camo)

YFM45FAV Kodiak 450 4WD 421cc 1D9 AJ15Y-0009601

YFM45FAHV Kodiak 450 4WD Hunter (Hardwoods® HD Camo) 421cc 1D9 AJ16Y-0005301

YFM45FXV Wolverine 450 4WD 421cc 3C2 AJ21Y-0000101

YFZ450V YFZ450 439cc 5TG AJ20Y-0000015

YFZ450BBV YFZ450 Bill Ballance Edition w/Kit 439cc 5TG AJ20Y-0000015

YFZ450SPV YFZ450 SP 50th Anniversary Edition 439cc 5TG AJ20Y-0000015

ATV 1/13/06 AT2006-001


PAGE 1 of 2




YFM66FAV Grizzly 660 4WD 660cc 2C6 AM03Y-0082365

YFM66FABGGV Grizzly 660 4WD Outdoorsman Edition w/Kit 660cc 2C6 AM03Y-0082365 Hunter Green

YFM66FABGHV Grizzly 660 4WD Outdoorsman Edition w/Kit 660cc 2C6 AM03Y-0082365 (Hardwoods® HD Camo)

YFM66FAHV Grizzly 660 4WD Hunter (Hardwoods® HD Camo) 660cc 2C6 AM03Y-0082365 YFM66FAHDV Grizzly 660 Ducks Unlimited® Edition 660cc 2C6 AM03Y-0082365

YFM66FASEV Grizzly 660 4WD SE 660cc 2C6 AM03Y-0082365

YFM700RV Raptor 700R 686cc 1S3 AM07Y-0000021

YFM700RSPV Raptor 700R SP 50th Anniversary Edition 686cc 1S3 AM07Y-0000021


PAGE 2 of 2


ATV 5/06/05 AT2005-003

2005 MODELSATV Paint Reference Chart

PAGE 1 of 6


This bulletin provides paint identification and ordering information for all 2005-model ATVs. All ATV paintmay be ordered through Color Rite:

Color Rite Distribution Company offers two ordering locations for your convenience. Color Rite East isfor dealers East of the Mississippi River. Color Rite West is for dealers West of the Mississippi River.Please note the new addresses below:

Color Rite Distribution CompanyColor Rite East Color Rite Dist. Co. (West)123 Blaine St. 1817 E. Ave. Q, Ste. C-24East Bangor, PA 18013 Palmdale, CA 93550800-358-1882 - Order 800-736-7980 - Order610-588-7355 - Tech 661-266-1944 - Tech610-588-1570 - Fax 661-266-0286 - Fax

E-Mail: [email protected] Site: www.color-rite.com.

As an added benefit, orders received by 2:00 pm (Eastern Standard Time for Color Rite East and PacificStandard Time for Color Rite West) will be shipped the same day.

When ordering, please provide the Year, Model, Paint Code, and call back information (e.g., phone num-ber / fax / e-mail). A Model Application Guide providing detailed information by model year can be foundat Color Rite’s web page:

www.color-rite.com

NOTE: The following paint chart is also very useful when ordering pre-painted and plastic body partsfrom the parts catalog. Paint codes are generally listed next to the part number of the pre-painted orplastic body part. This chart can be used to confirm the color of the part you are ordering. The Salescolor name may be used for more than one paint color.

For previous model year paint information, please refer to the following:• (’91~’99) Paint Reference Guide (P/N: LIT-10030-PC-99)• (’91~’99) Summer ’99 Paint Chart Reference Guide (P/N: LIT-10030-PC-2K)• (’99~’00) ATV Paint Reference Chart (Technical Bulletin AT2001-005)• (2001) ATV Paint Reference Chart (Technical Bulletin AT2001-003) • (2002) ATV Paint Reference Chart (Technical Bulletin AT2001-009)• (2003) ATV Paint Reference Chart (Technical Bulletin AT2003-002)• (2004) ATV Paint Reference Chart (Technical Bulletin AT2004-004)

“Grizzly 660 Auto 4x4” 2C61 Hunter Edition Body* N/A(Hardwoods® Camo (Realtree Hardwoods® Frame Yamaha Black 0033 Hunter Edition Camouflage) Front Bumper Low Gloss Black 0098 YFM66FAHT Carrier (F&R) Chijimi Black 00W0

Wheel Low Gloss Black 0098

“Grizzly 660 Auto 4x4” 2C62 Hunter Edition Body* N/A(Wetlands™ Camo (Advantage® Wetlands™ Frame Yamaha Black 0033 Hunter Edition) Camouflage) Front Bumper Low Gloss Black 0098 YFM66FAHWT Carrier (F&R) Chijimi Black 00W0


“Grizzly 660 Auto 4x4” 2C63 Metallic Black Body Black Metallic L 0965 YFM660FASET (Special Edition) Frame Yamaha Black 0033

Front Bumper Silver 8 0095 Carrier (F&R) Chijimi Black 00W0 Wheel No paint

“Grizzly 660 Auto 4x4” 5KMU Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM66FAT Frame Yamaha Black 0033

Front Bumper Titanic Gray Metallic 00MACarrier (F&R) Chijimi Black 00W0 Wheel No paint

Steel Blue (L) Body* Dark Purplish Blue Solid N 0891 Frame Yamaha Black 0033 Front Bumper Titanic Gray Metallic 00MACarrier (F&R) Chijimi Black 00W0 Wheel No paint

Red (R) Body* Romantique Rouge 00TR Frame Yamaha Black 0033 Front Bumper Titanic Gray Metallic 00MACarrier (F&R) Chijimi Black 00W0 Wheel No paint

“Kodiak 450 Auto 4X4” 1D95 Hunter Edition Body* N/A(Hardwoods® Camo (Realtree Hardwoods® Frame Yamaha Black 0033 Hunter Edition) Camouflage) Front Bumper Chijimi Black 00W0 YFM45FAHT Carrier (F&R) Chijimi Black 00W0


“Kodiak 450 Auto 4X4” 1D98 Metallic Black Body Black Metallic L 0965YFM45FASET (Special Edition) Frame Low Gloss Black 0098

Front Bumper Silver 8 0895Carrier (F&R) Chijimi Black 00W0Wheel Low Gloss Black 0098

“Kodiak 450 Auto 4X4” 1D91 Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM45FAT Frame Yamaha Black 0033

Front Bumper Chijimi Black 00W0 Carrier (F&R) Chijimi Black 00W0 Wheel Titanic Gray Metallic 00MA

Steel Blue (L) Body* Dark Purplish Blue Solid N 0891 Frame Yamaha Black 0033 Front Bumper Chijimi Black 00W0 Carrier (F&R) Chijimi Black 00W0 Wheel Titanic Gray Metallic 00MA

Red (R) Body* Romantique Rouge 00TR Frame Yamaha Black 0033 Front Bumper Chijimi Black 00W0 Carrier (F&R) Chijimi Black 00W0 Wheel Titanic Gray Metallic 00MA

2005 ATV Paint Reference Chart MODEL SALES PAINT YAMAHA COLOR RITE

MODEL CODE COLOR NAME COMPONENT COLOR NAME PAINT CODE PAINT CODE

NOTE: When orderingpre-painted or plasticbody parts from the Parts Catalog, checkthe first page of the parts list, the code next to the part number, and this chart for color verification.

The Sales ColorName is for unitcolor identificationand may be usedfor more than onepaint color.

Modelcodes canbe used toconfirm themodel yearof the unit.

N/A - Not Available.

Color-Rite Paint Code Information:1000 series codes are base coats.5000 series codes are color coats.All color coats must be clear coated.Use low gloss clear for low gloss paint.

*Paint code for ref-erence only - Donot paint plasticbody.

PAGE 2 of 6

513556545187^5654

513556545187^5654

TBA513552655187^

5822513558605187^

5290513558605187^

5650513558605187^

51355187^5187^5654

TBA565452655187*5654

582251355187^5187^5860

529051355187^5187^5860

565051355187^5187^5860

^5187 is nottextured.

(YB)(LGB)(WVB) (LGB)


(SML)(YB)(S8)(WVB)

(PDG) (YB)(TGM)(WVB)

(DPBSN)(YB)(TGM)(WVB)

(RTR)(YB)(TGM)(WVB)

(YB)(WVB)(WVB)(LGB)

(SML)(LGB)(S8)(WVB)((LGB)

(PDG)(YB)(WVB)(WVB)(TGM)

(DPBSN)(YB)(WVB)(WVB)(TGM)

(RTR)(YB)(WVB)(WVB)(TGM)

UTILITY

TBA – To BeAnnounced

“Kodiak 400 Auto 4x4” 1P14 Hunter Edition Body* N/A(Hardwoods® Camo (Realtree Hardwoods® Frame Yamaha Black 0033 Hunter Edition) Camouflage) Front Bumper Chijimi Black 00W0 YFM4FAHT Carrier (F&R) Chijimi Black 00W0


“Kodiak 400 Auto 4X4” 1P11 Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM4FAT Frame Yamaha Black 0033

Front Bumper Chijimi Black 00W0 Carrier (F&R) Chijimi Black 00W0 Wheel Low Gloss Black 0098

Steel Blue (L) Body* Dark Purplish Blue Solid N 0891 Frame Yamaha Black 0033 Front Bumper Chijimi Black 00W0 Carrier (F&R) Chijimi Black 00W0 Wheel Low Gloss Black 0098

Red (R) Body* Romantique Rouge 00TR Frame Yamaha Black 0033 Front Bumper Chijimi Black 00W0 Carrier (F&R) Chijimi Black 00W0 Wheel Low Gloss Black 0098

“Big Bear 400 4X4” 5FUF Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM40FT Frame Yamaha Black 0033




“Wolverine” 2D41 Black (B) Body* Yamaha Black 0033 YFM35FXT Frame Yamaha Black 0033

Front Bumper Silver 8 0895 Carrier (R) Yamaha Black 0033 Wheel Silver 0035

White/Red (W) Body* Bluish White Solid 1 0892 Frame Yamaha Black 0033 Front Bumper Vivid Red Cocktail 7 0580 Carrier (R) Yamaha Black 0033 Wheel Silver 0035

“Bruin 350 Auto 4x4” 5UHA Hunter Edition Body* N/A(Hardwoods® Camo (Realtree Hardwoods® Frame Yamaha Black 0033 Hunter Edition) Camouflage) Front Bumper Chijimi Black 00W0 YFM35FAHT Carrier (F&R) Chijimi Black 00W0




NOTE: When orderingpre-painted or plasticbody parts from the Parts Catalog, checkthe first page of the parts list, the code next to the part number, andthis chart for colorverification.





51355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654

51355135526551355616

578051351300-1 + 582651355616

51355187^5187^5654


PAGE 3 of 6

(YB)(WVB)(WVB)(LGB)

(PDG)(YB)(WVB)(WVB)(LGB)

(DPBSN)(YB)(WVB)(WVB)(LGB)

(RTR)(YB)(WVB)(WVB)(LGB)




(YB) (YB)(S8)(YB)(SL)

(BWS1)(YB)(VRC7)(YB)(SL)

(YB)(WVB)(WVB) (LGB)

UTILITY (CONT’D)

N/A – NotApplicable

“Bruin 350 Auto 4x4” 5UH6 Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM35FAT Frame Yamaha Black 0033




“Bruin 350 Automatic” 5WH4 Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM35BAT Frame Yamaha Black 0033




“Bruin 250” 1P01 Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM250BT Frame Yamaha Black 0033




“Grizzly 125” 1C58 Hunter Edition Body* N/A(Hardwoods® Camo (Realtree Hardwoods® Frame Yamaha Black 0033Hunter Edition) Camouflage) Front Bumper Mat Black 2 0582 YFM125GHT Carrier (F&R) Mat Black 2 0582


“Grizzly 125” 1C55 Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM125GT Frame Yamaha Black 0033

Front Bumper Mat Black 2 0582 Carrier (F&R) Mat Black 2 0582 Wheel Silver 0035

Steel Blue (L) Body* Dark Puplish Blue Solid N 0891 Frame Yamaha Black 0033 Front Bumper Mat Black 2 0582 Carrier (F&R) Mat Black 2 0582 Wheel Silver 0035



NOTE: When orderingpre-painted or plastic body parts from the Parts Catalog,check the first page of the parts list, the code next to the part number, andthis chart for color verification.



N/A – Not Available.



582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654

5650 51355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654

5135598859885654

58225135598859885616

52905135598859885616


(PDG)(YB)(WVB)(WVB) (LGB)

(DPBSN)(YB)(WVB)(WVB) (LGB)

(RTR) (YB)(WVB)(WVB)(LGB)







(YB)(MBL2)(MBL2)(LGB)

(PDG)(YB)(MBL2)(MBL2)(SL)

(DPBSN)(YB)(MBL2)\(MBL2)(SL)

PAGE 4 of 6

UTILITY (CONT’D)

“Bruin 350 Auto 4x4” 5UH6 Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM35FAT Frame Yamaha Black 0033




“Bruin 350 Automatic” 5WH4 Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM35BAT Frame Yamaha Black 0033




“Bruin 250” 1P01 Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM250BT Frame Yamaha Black 0033




“Grizzly 125” 1C58 Hunter Edition Body* N/A(Hardwoods® Camo (Realtree Hardwoods® Frame Yamaha Black 0033Hunter Edition) Camouflage) Front Bumper Mat Black 2 0582 YFM125GHT Carrier (F&R) Mat Black 2 0582


“Grizzly 125” 1C55 Hunter Green (GR) Body* Pastel Deep Green 00K0 YFM125GT Frame Yamaha Black 0033


Steel Blue (L) Body* Dark Puplish Blue Solid N 0891 Frame Yamaha Black 0033 Front Bumper Mat Black 2 0582 Carrier (F&R) Mat Black 2 0582 Wheel Silver 0035






N/A – Not Available.



582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654

5650 51355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654

5135598859885654

58225135598859885616

52905135598859885616











(YB)(MBL2)(MBL2)(LGB)


(DPBSN)(YB)(MBL2)\(MBL2)(SL)

PAGE 4 of 6

UTILITY (CONT’D)

“660R Raptor” Special Edition 5LPT Sport Camo Body* Dark Gray Metallic E 0952 YFM660RSET Frame Silver 8 0895

Front Bumper Silver 8 0895 Wheel No paint

“660R Raptor” 5LPP Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 YFM660RT White (L) Frame Silver 8 0895

Front Bumper Silver 8 0895 Wheel no paint

White / (W) Body (Primary)* Bluish White Solid 1 0892 Red Body (Secondary)* Vivid Red Cocktail 7 0580

Frame Vivid Red Cocktail 7 0580 Front Bumper Silver 8 0895 Wheel no paint

“YFZ450” Special Edition 5TGA Yellow/ Body (Primary)* Light Reddish Yellow Solid 1 0386YFZ450SET Black Body (Secondary)* Yamaha Black 0033

Frame Mat Black 2 0582Front Bumper Silver 8 0895Wheel no paint

“YFZ450” 5TG7 Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 YFZ450T White (L) Frame Silver 8 0895


White / (W) Body* Bluish White Solid 1 0892 Red Frame Vivid Red Cocktail 7 0580


“Banshee” Special Edition 5FKY Black Body* Black Metallic J 0906 YFZ350SET Frame Mat Black 2 0582


“Banshee” 5FKV Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 YFZ350T White (L) Frame Silver 8 0895

Front Bumper Silver 8 0895 (S8) Wheel no paint

White / (W) Body (Primary)* Bluish White Solid 1 0892 Red Body (Secondary)* Vivid Red Cocktail 7 0580

Frame Vivid Red Cocktail 7 0580 Front Bumper Silver 8 0895 (S8) Wheel no paint

“Raptor 350” Special Edition 5YT4 Grey Body* Dark Gray Metallic E 0952YFM350RSET Frame Mat Black 2 0582

Front Bumper no paintWheel no paint

“Raptor 350” 5YT5 Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 YFM350RT White (L) Frame Silver 8 0895


White / (W) Body (Primary)* Bluish White Solid 1 0892 Red Body (Secondary)* Romantique Rouge 00TR

Frame Vivid Red Cocktail 7 0580 Front Bumper no paintWheel no paint



TBA52655265

582952655265

57801300-1 + 58261300-1 + 58265265

5809513559885265

582952655265

57801300-1 + 58265265

TBA59885265

582952655265

57801300-1 + 58261300-1 + 58265265

TBA5988

58295265

578056501300-1 + 5826



Modelcodes canbe used toconfirm themodel yearof the unit. Color-Rite Paint Code Information:

1000 series codes are base coats.5000 series codes are color coats.All color coats must be clear coated.Use low gloss clear for low gloss paint.


PAGE 5 of 6

(DGME)(S8)(S8)

(DPBSE)(S8)(S8)

(BWS1)(VRC7)(VRC7)(S8)

(LYRS1)(YB)(MBL2)(S8)

(DPBSE)(S8)(S8)

(BWS1)(VRC7)(S8)

(SMJ)(MBL2)(S8)

(DPBSE)(S8)

(BWS1)VRC7)(VRC7)

(DGME)(MBL2)

(DPBSE)(S8)

(BWS1)(RTR(VRC7)

SPORT

TBA – To BeAnnounced

“Blaster” 5VM5 Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFS200T White (L) Frame Silver 8 0895 (S8)

Front Bumper Silver 8 0895 (S8) Wheel Silver 0035 (SL)

White / (W) Body* Bluish White Solid 1 0892 (BWS1) Red Frame Vivid Red Cocktail 7 0580 (VRC7)


“Grizzly 80” 2D31 Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG)YFM80GT Frame Yamaha Black 0033 (YB)

Front Bumper Mat Black 2 0582 (MBL2)Carrier Mat Black 2 0582 (MBL2)Wheel Silver 0035 (SL)

Steel Blue (L) Body* Dark Purplish Blue Solid N 0891 (DPBSN)Frame Yamaha Black 0033 (YB)Front Bumper Mat Black 2 0582 (MBL2)Carrier Mat Black 2 0582 (MBL2)Wheel Silver 0035 (SL)

“Raptor 80” 5THB Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFM80RT White (L) Frame Yamaha Black 0033 (YB)


White / (W) Body (Primary)* Bluish White Solid 1 0892 (BWS1) Red Body (Secondary)* Romantique Rouge 00TR (RTR)

Frame Yamaha Black 0033 (YB) Front Bumper Silver 8 0895 (S8) Wheel Silver 0035 (SL)

“Raptor 50” 5FY4 Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFM50RT White (L) Frame Yamaha Black 0033 (YB)


White / (W) Body (Primary)* Bluish White Solid 1 0892 (BWS1) Red Body (Secondary)* Romantique Rouge 00TR (RTR)









5829526552655616

57801300-1 + 582652655616

58225135598859885616

52905135598859885616

5829513552655616

57805650513552655616

5829513552655616

57805650513552655616

PAGE 6 of 6

YOUTH

ROUTE TO: SERVICE PARTS WARRANTY SALES

SPORT (CONT’D)



YFM50RT Raptor 50 49cc 5YF AA013-0007523YFM80RT Raptor 80 79cc 5TH AB02Y-0030027YFM80GT Grizzly 80 79cc 2D3 AB03Y-0000011YFM125GT Grizzly 125 124cc 1C5 AE02Y-0002513YFM125GHT Grizzly 125 (Hunter Green) 124cc 1C5 AE02Y-0002513YFS200T Blaster 195cc 5VM AG023-0026699YFM250BT Bruin 250 2WD 230cc 1P01 AG01Y-0112201YFM350RT Raptor 350 348cc 5YT AH12Y-0004796YFM350RSET Raptor 350 SE (Special Edition) 348cc 5YT AH12Y-0017518YFM35FXT Wolverine 4WD 348cc 4KB AH04Y-0018609YFZ350T Banshee 347cc 5FK 3GG03-0057019YFZ350SET Banshee SE (Special Edition) 347cc 5FK 3GG03-0057019YFM35BAT Bruin 350 Auto 2WD 348cc 5WH AH10Y-0007701YFM35FAT Bruin 350 Auto 4WD 348cc 5UH AH09Y-0012301YFM35FAHT Bruin 350 Auto 4WD (Hunter Edition) 348cc 5UH AH13Y-0000101YFM40FT Big Bear 400 4WD 386cc 5FU AH06Y-0052201YFM4FAT Kodiak 400 4WD 401cc 1P1 AJ15Y-0000101YFM4FAHT Kodiak 400 4WD (Hunter Edition) 401cc 1P1 AJ15Y-0000101YFM45FAT Kodiak 450 4WD 421cc 1D9 AJ14Y-0000101YFM45FAHT Kodiak 450 4WD (Realtree Hardwoods® Hunter

Edition) 421cc 1D9 AJ16Y-0000101

YFZ450T YFZ450 439cc 5TG AJ11Y-0023898YFZ450RSET YFZ450 SE (Special Edition) 439cc 5TG AJ11Y-0023898YFM660RT 660R Raptor 660cc 5LP AM01Y-0064904 YFM660RSET 660R Raptor SE (Special Edition) 660cc 5LP AM01Y-0064904 YFM66FAT Grizzly 660 4WD 660cc 5KM AM03Y-0051677YFM66FAHT Grizzly 660 4WD (Realtree Hardwoods® Hunter

Edition) 660cc 5KM AM03Y-0051677

YFM66FAHWT Grizzly 660 4WD (Realtree Wetlands™ HunterEdition) 660cc 5KM AM03Y-0051677

YFM66FASET Grizzly 660 4WD (Special Edition) 660cc 5KM AM03Y-0051677

ATV 3/24/05 AT2005-001


PAGE 1 of 1


The following is a comprehensive listing of Primary ID numbers for 2005 Yamaha ATVs. The frame num-ber of a unit contains the Primary ID for warranty purposes. Production started with the listed numbersbelow. For more Primary ID details, see Technical Bulletin AT97-006 or AT99-003. The Model Codeappears on a label on the ATV and is useful to help identify the model when contacting Yamaha Parts& Accessories. This code is also referenced with other model information at the beginning of the PartsList on CD-ROM.Model Model Name Displacement Model Code Starting PID No.


ATV 5/14/04 AT2004-004


PAGE 1 of 6

© 2004 YAMAHA MOTOR CORPORATION, U.S.A.


Color Rite Distribution Company now offers two ordering locations for your convenience. Color Rite Eastis for dealers East of the Mississippi River. Color Rite West is for dealers West of the Mississippi River.Please note the new address below:

Color Rite Distribution CompanyColor Rite East Color Rite Dist. Co. (West)123 Blaine St. 1817 E. Ave. Q, Ste. C-24East Bangore, PA 18013 Palmdale, CA 93550800-358-1882 - Order 800-736-7980 - Order610-588-7355 - Tech 661-266-1944 - Tech610-588-1570 - Fax 661-266-0286 - Fax

E-Mail: [email protected] Site: www.color-rite.com.


When ordering, please provide Color Rite with the Year, Model, and Paint Code. Remember to providecall back information for your dealership (e.g., phone number / fax / e-mail). A Model Application Guideproviding detailed information by model year can be found at Color Rite’s web page:

www.color-rite.comNOTE: The following paint chart is also very useful when ordering pre-painted and plastic body partsfrom the parts catalog. Paint codes are generally listed next to the part number of the pre-painted orplastic body part. This chart can be used to confirm the color of the part you are ordering. The Salescolor name may be used for more than one paint color.

For previous model year paint information, please refer to the following:• (’91~’99) Paint Reference Guide (P/N: LIT-10030-PC-99)• (’91~’99) Summer ’99 Paint Chart Reference Guide (P/N: LIT-10030-PC-2K)• (’99~’00) ATV Paint Reference Chart (Technical Bulletin AT2001-005)• (2001) ATV Paint Reference Chart (Technical Bulletin AT2001-003) • (2002) ATV Paint Reference Chart (Technical Bulletin AT2001-009)• (2003) ATV Paint Reference Chart (Technical Bulletin AT2003-002)

Grizzly 660 Auto 4x4 5KMM Hunter Edition Body* N/AYFM660FHS (Realtree Hardwoods® Frame Yamaha Black 0033 Realtree Hardwoods® Camo Camouflage) Front Bumper Low Gloss Black 0098 Hunter Edition Carrier (F&R) Chijimi Black 00W0


Grizzly 660 Auto 4x4 5KMN Hunter Edition Body* N/AYFM660FHSWL (Advantage® Wetlands™ Frame Yamaha Black 0033 Realtree® Wetlands™ Camo Camouflage) Front Bumper Low Gloss Black 0098 Hunter Edition Carrier (F&R) Chijimi Black 00W0


Grizzly 660 Limited Edition 5KMP Limited Edition Metallic Body Dull Red Metallic D 0779 Auto 4x4 Red Frame Yamaha Black 0033 YFM660FLES Front Bumper Low Gloss Black 0098

Carrier (F&R) Chijimi Black 00W0 Wheel No paint

Grizzly 660 Auto 4x4 5KMH Hunter Green Body* Pastel Deep Green 00K0 YFM660FS Frame Yamaha Black 0033


Steel Blue Body* Dark Purplish Blue Solid N 0891 Frame Yamaha Black 0033 Front Bumper Titanic Gray Metallic 00MACarrier (F&R) Chijimi Black 00W0 Wheel No paint

Red Body* Romantique Rouge 00TR Frame Yamaha Black 0033 Front Bumper Titanic Gray Metallic 00MACarrier (F&R) Chijimi Black 00W0 Wheel No paint

Kodiak 450 4x4 Ultramatic 5NDC Hunter Edition Body* N/AYFM45FAHS (Realtree Hardwoods® Frame Yamaha Black 0033 Realtree Hardwoods® Camo Camouflage) Front Bumper Chijimi Black 00W0 Hunter Edition Carrier (F&R) Chijimi Black 00W0


Kodiak 450 4X4 Ultramatic 5ND6 Hunter Green Body* Pastel Deep Green 00K0 YFM45FAS Frame Yamaha Black 0033


Steel Blue Body* Dark Purplish Blue Solid N 0891 Frame Yamaha Black 0033 Front Bumper Chijimi Black 00W0 Carrier (F&R) Chijimi Black 00W0 Wheel Titanic Gray Metallic 00MA

Red Body* Romantique Rouge 00TR Frame Yamaha Black 0033 Front Bumper Chijimi Black 00W0

Carrier (F&R) Chijimi Black 00W0 Wheel Titanic Gray Metallic 00MA

Kodiak 400 4x4 Ultramatic 5TEA Hunter Edition Body* N/AYFM4FAHS (Realtree Hardwoods® Frame Yamaha Black 0033 Realtree Hardwoods® Camo Camouflage) Front Bumper Chijimi Black 00W0 Hunter Edition Carrier (F&R) Chijimi Black 00W0




C - DesignatesCalifornia Model

NOTE: When orderingpre-painted or plasticbody parts from the Parts Catalog, checkthe first page of the parts list, the code next to the part number, and this chart for color verification.






PAGE 2 of 6

513556545187^5654

513556545187^5654

1165 + 5165513556545187^

5822513558605187^

5290513558605187^

5650513558605187^

51355187^5187^5654

582251355187^5187^5860

529051355187^5187^5860

565051355187^5187^5860

51355187^5187^5654




(DRMD)(YB)(LGB)(WVB)

(PDG) (YB)(TGM)(WVB)

(DPBSN)(YB)(TGM)(WVB)

(RTR)(YB)(TGM)(WVB)

(YB)(WVB)(WVB)(LGB)


(DPBSN)(YB)(WVB)(WVB)(TGM)


(YB)(WVB)(WVB)(LGB)

UTILITY

Kodiak 400 Ultramatic 4X4 5TE6 Hunter Green Body* Pastel Deep Green 00K0 YFM4FAS Frame Yamaha Black 0033


Steel Blue Body* Dark Purplish Blue Solid N 0891 Frame Yamaha Black 0033 Front Bumper Chijimi Black 00W0 Carrier (F&R) Chijimi Black 00W0 Wheel Low Gloss Black 0098

Red Body* Romantique Rouge 00TR Frame Yamaha Black 0033 Front Bumper Chijimi Black 00W0 Carrier (F&R) Chijimi Black 00W0 Wheel Low Gloss Black 0098

Kodiak 400 Ultramatic 2WD 5VH5 Hunter Green Body* Pastel Deep Green 00K0 YFM4AS Frame Yamaha Black 0033




Big Bear 400 4X4 5FUE Hunter Green Body* Pastel Deep Green 00K0 YFM40FS Frame Yamaha Black 0033




Big Bear 400 2WD 5GWB Hunter Green Body* Pastel Deep Green 00K0 YFM40S Frame Yamaha Black 0033











582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654


PAGE 3 of 6












UTILITY (CONT’D)

Bruin 350 Auto 4x4 5UH3 Hunter Edition Body* N/AYFM35FAHS (Realtree Hardwoods® Frame Yamaha Black 0033 Realtree Hardwoods® Camo Camouflage) Front Bumper Chijimi Black 00W0 Hunter Edition Carrier (F&R) Chijimi Black 00W0


Bruin 350 Auto 4x4 5UH1 Hunter Green Body* Pastel Deep Green 00K0 YFM35FAS Frame Yamaha Black 0033




Bruin 350 Auto 2WD 5WH1 Hunter Green Body* Pastel Deep Green 00K0 YFM35AS Frame Yamaha Black 0033




Wolverine 4X4 4KBX Team Yamaha Blue Body* Deep Purplish Blue Solid E 0583 YFM35FXS Frame Yamaha Black 0033


Black Body* Yamaha Black 0033 Frame Yamaha Black 0033 Front Bumper Mat Black 2 0582 Carrier (R) Yamaha Black 0033 Wheel Low Gloss Black 0098

BearTracker 4XEL Hunter Green Body* Pastel Deep Green 00K0 YFM250XS Frame Yamaha Black 0033













51355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654

582251355187^5187^5654

529051355187^5187^5654

5650 51355187^5187^5654

58295135526551355616

51355135598851355654

582251355187^5187^5654

529051355187^5187^5654

565051355187^5187^5654









(DPBSE) (YB)(S8)(YB)(SL)

(YB)(YB)(MBL2)(YB)(LGB)




PAGE 4 of 6

UTILITY (CONT’D)

Bruin 350 Auto 4x4 5UH3 Hunter Edition Body* N/AYFM35FAHS (Realtree Hardwoods® Frame Yamaha Black 0033 Realtree Hardwoods® Camo Camouflage) Front Bumper Chijimi Black 00W0 Hunter Edition Carrier (F&R) Chijimi Black 00W0


Bruin 350 Auto 4x4 5UH1 Hunter Green Body* Pastel Deep Green 00K0 YFM35FAS Frame Yamaha Black 0033




Bruin 350 Auto 2WD 5WH1 Hunter Green Body* Pastel Deep Green 00K0 YFM35AS Frame Yamaha Black 0033




Wolverine 4X4 4KBX Team Yamaha Blue Body* Deep Purplish Blue Solid E 0583 YFM35FXS Frame Yamaha Black 0033


Black Body* Yamaha Black 0033 Frame Yamaha Black 0033 Front Bumper Mat Black 2 0582 Carrier (R) Yamaha Black 0033 Wheel Low Gloss Black 0098

BearTracker 4XEL Hunter Green Body* Pastel Deep Green 00K0 YFM250XS Frame Yamaha Black 0033













51355187^5187^5654

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(DPBSE) (YB)(S8)(YB)(SL)

(YB)(YB)(MBL2)(YB)(LGB)




PAGE 4 of 6

UTILITY (CONT’D)

125 Grizzly 1C51 Hunter Green Body* Pastel Deep Green 00K0 YFM125S Frame Yamaha Black 0033


Steel Blue Body* Dark Puplish Blue Solid N 0891 Frame Yamaha Black 0033 Front Bumper Mat Black 2 0582 Carrier (F&R) Mat Black 2 0582 Wheel Silver 0035

Breeze 5VJ4/5VJ5 Team Yamaha Blue Body* Deep Purplish Blue Solid E 0583 YFA1S/C Frame Yamaha Black 0033

Front Bumper Yamaha Black 0033 Wheel Silver 0035

Hunter Green Body* Pastel Deep Green 00K0 Frame Yamaha Black 0033 Front Bumper Yamaha Black 0033 Wheel Silver 0035

660R Raptor 5LPF Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 YFM660RS White Frame Silver 8 0895


White / Body* Bluish White Solid 1 0892 Red Body Vivid Red Cocktail 7 0580

Frame Vivid Red Cocktail 7 0580 Front Bumper Silver 0035 Wheel no paint

660R Raptor Limited Edition 5LPJ Black / Yellow Body* Yamaha Black 0033 YFM660RLES Body Silver 3 0791

Frame Mat Black 2 0582 Front Bumper Mat Black 2 0582 Wheel Low Gloss Black 0098

YFZ450 5TG1 Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 YFZ450S White Frame Silver 8 0895


White / Body* Bluish White Solid 1 0892 Red Body Vivid Red Cocktail 7 0580

Frame Vivid Red Cocktail 7 0580 Front Bumper Silver 8 0895 Wheel no paint

YFZ450 Limited Edition 5TG4 Black / Yellow Body* Yamaha Black 0033YFM450LES Frame Mat Titan 2 0826

Front Bumper Mat Titan 2 0826Wheel Low Gloss Black 0098

Raptor 350 5YT1 Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 YFM350S White Frame Silver 8 0895


White / Body* Bluish White Solid 1 0892 Red Body Romantique Rouge 00TR

Frame Vivid Red Cocktail 7 0580 Front Bumper no paintWheel no paint



58225135598859885616

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PAGE 5 of 6


(DPBSN)(YB)(MBL2)(MBL2)(SL)

(DPBSE)(YB)(YB)(SL)

(PDG)(YB)(YB)(SL)

(DPBSE)(S8)(S8)

(BWS1)(VRC7)(VRC7)(SL)

(YB)(S3)(MBL2)(MBL2)(LGB)

(DPBSE)(S8)(S8)

(BWS1)(VRC7)(VRC7)(S8)

(YB)(MT2)(MT2)(LGB)

(DPBSE)(S8)

(BWS1)(RTR)(VRC7)

UTILITY (CONT’D)

SPORT

Banshee 5FKP Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFZ350S White Frame Silver 8 0895 (S8)


White / Body* Bluish White Solid 1 0892 (BWS1) Red Body Vivid Red Cocktail 7 0580 (VRC7)

Frame Vivid Red Cocktail 7 0580 (VRC7) Front Bumper Silver 8 0895 (S8) Wheel no paint

Banshee Limited Edition 5FKT Black / Yellow Body* Yamaha Black 0033 (YB) YFZ350LES Frame Mat Black 2 0582 (MBL2)

Front Bumper Mat Black 2 0582 (MBL2)Wheel Low Gloss Black 0098 (LGB)

Warrior 5NFB / Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFM35XS(C) 5NFC White Frame Silver 8 0895 (S8)


White / Body* Bluish White Solid 1 0892 (BWS1) Red Frame Vivid Red Cocktail 7 0580 (VRC7)


Blaster 5VM3 Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFS200S White Frame Silver 8 0895 (S8)


White / Body* Bluish White Solid 1 0892 (BWS1) Red Frame Vivid Red Cocktail 7 0580 (VRC7)


Raptor 80 5TH8 Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFM80WS White Frame Yamaha Black 0033 (YB)


White / Body* Bluish White Solid 1 0892 (BWS1) Red Body Romantique Rouge 00TR (RTR)


Raptor 50 5YF1 Team Yamaha Blue / Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFM50S White Frame Yamaha Black 0033 (YB)


White / Body* Bluish White Solid 1 0892 (BWS1) Red Body Romantique Rouge 00TR (RTR)










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PAGE 6 of 6

YOUTH


SPORT (CONT’D)

ATV 4/23/04 AT2004-003


PAGE 1 of 3


This bulletin contains a comprehensive listing of Service Literature Part Numbers for 2004 models.Certain models will not have new literature if the prior year’s information is still current. The manuals list-ed in the chart below can be ordered from Crestec Los Angeles, Inc. (Ph: 1-888-530-9446, FAX: 1-310-527-5835). This bulletin also lists other publications related to your dealership operation (see page 3),which can be ordered from Yamaha Parts and Accessories.

YFM50WS Raptor 50 LIT-11626-17-13 LIT-11616-17-13 LIT-11666-17-13

YFM80WS Raptor 80 LIT-11626-17-12 YFM80WD~M YFM80WP LIT-11616-YF-81 YFM80WPLIT-11616-YF-80 LIT-11616-15-38 LIT-11666-15-38

YFA1S Breeze LIT-11626-17-02 YFA1W(~N) YFA1P LIT-11616-YF-01 LIT-11666-17-02LIT-11616-YF-00 LIT-11616-15-08

YFA1SC Breeze (Calif.) LIT-11626-17-02 YFA1W(~N) YFA1P LIT-11616-YF-01 LIT-11666-17-02LIT-11616-YF-00 LIT-11616-15-08

YFM125S Grizzly 125 LIT-11626-17-56 YFA1W(~N) YFA1P LIT-11616-GZ-12 LIT-11666-17-56LIT-11616-YF-00 LIT-11616-15-08

YFM125S LIT-11616-17-56

YFS200S Blaster LIT-11626-17-07 YFS200U YFS200P LIT-11616-BL-20 LIT-11666-17-07LIT-11616-07-20 LIT-11616-15-05

YFS200RLIT-11616-16-37

YFM25XS BearTracker LIT-11626-17-22 YFM250XL YFM250XN LIT-11616-BT-25 YFM250XLLIT-11616-12-01 LIT-11616-14-17 LIT-11666-12-01

YFM250XPLIT-11616-15-03

YFM35AS Bruin 350 2WD LIT-11626-17-33 YFM400FAR YFM350AS LIT-11616-BN-20 LIT-11666-17-33LIT-11616-16-02 LIT-11616-17-33

YFM350S Raptor 350 LIT-11626-17-57 YFM350XA(~N) YFM350XP LIT-11616-RP-35 LIT-11666-17-57LIT-11616-YM-37 LIT-11616-15-09

YFM350ZSLIT-11616-17-57

YFM35FAS Bruin 350 4x4 LIT-11626-17-32 YFM400FAR YFM350AS LIT-11616-BN-35 LIT-11666-17-32LIT-11616-16-02 LIT-11616-17-32

YFM35FAHS Bruin 350 4x4 LIT-11626-17-32 YFM400FAR YFM350AS LIT-11616-BN-35 LIT-11666-17-32Hardwoods® LIT-11616-16-02 LIT-11616-17-32Hunter

YFM35FXS Wolverine 4x4 LIT-11626-17-03 YFM350FXG(~M) YFM350FXN LIT-11616-FX-37 YFM35FXGLIT-11616-FX-36 LIT-11616-14-02 LIT-11666-09-58

YFM350FXPLIT-11616-15-07

Model Owner’s Service Manual Supplements Compilation Manual AssemblyModel Name Manual (Main) (Supplements Only) (Main & Supplements) Manual

PAGE 2 of 3

YFM35XS Warrior LIT-11626-17-06 YFM350XA(~N) YFM350XP LIT-11616-YM-38 LIT-11666-17-06LIT-11616-YM-37 LIT-11616-15-09

YFM35XSC Warrior (Calif.) LIT-11626-17-06 YFM350XA(~N) YFM35XP LIT-11616-YM-38 LIT-11666-17-06LIT11616-YM-37 LIT-11616-15-09

YFZ350S Banshee LIT-11626-17-04 YFZ350T(~N) YFZ350P LIT-11616-YF-37 LIT-11666-17-04LIT-11616-YF-36 LIT-11616-15-04

YFZ350LES Banshee LIT-11626-17-04 YFZ350T(~N) YFZ350P LIT-11616-YF-37 LIT-11666-17-04Limited Edition LIT-11616-YF-36 LIT-11616-15-04

YFM4AS Kodiak 400 2WD LIT-11626-17-18 YFM400FAR YFM400AR LIT-11616-KD-20 YFM400ARUltramatic LIT-11616-16-02 LIT-11616-16-35 LIT-11666-16-35

YFM4FAS Kodiak 400 4x4 LIT-11626-17-17 YFM400FAR YFM400FAR Ultramatic LIT-11616-16-02 LIT-11666-16-02

YFM4FAHS Kodiak 400 4x4 LIT-11626-17-17 YFM400FAR YFM400FAR Hunter Ultramatic LIT-11616-16-02 LIT-11666-16-02

YFM40S Big Bear 400 2WD LIT-11626-17-08 YFM400FWNM(~N) YFM400P LIT-11616-BB-20 YFM400MLIT-11616-BB-2K LIT-11616-15-21 LIT-11666-13-34

YFM40FS Big Bear 400 4x4 LIT-11626-17-10 YFM400FM YFM40FP LIT-11616-BB-40 YFM400FWNMLIT-11616-BB-2K LIT-11616-15-22 LIT-11666-13-22

YFM45FAS Kodiak 450 4x4 LIT-11626-17-25 YFM450FAR YFM450FAS LIT-11616-KD-45 YFM450FARUltramatic LIT-11616-16-01 LIT-11616-17-25 LIT-11666-16-01

YFM45FAHS Kodiak 450 4x4 LIT-11626-17-25 YFM450FAR YFM450FAS LIT-11616-KD-45 YFM450FARHardwoods® LIT-11616-16-01 LIT-11616-17-25 LIT-11666-16-01Hunter Ultramatic

YFZ450S YFZ450 LIT-11626-17-11 LIT-11616-17-11 LIT-11666-17-11YFM660FS Grizzly 660 LIT-11626-17-14 YFM660FP YFM660FR LIT-11616-GZ-66 YFM660FP

LIT-11616-15-01 LIT-11616-16-34 LIT-11666-15-01YFM660FS

LIT-11616-17-14

YFM660FHS Grizzly 660 LIT-11626-17-14 YFM660FP YFM660FR LIT-11616-GZ-66 YFM660FPHardwoods® LIT-11616-15-01 LIT-11616-16-34 LIT-11666-15-01Hunter YFM660FS

LIT-11616-17-14

YFM660FLES Grizzly 660 LIT-11626-17-14 YFM660FP YFM660FR LIT-11616-GZ-66 YFM660FPLimited Edition LIT-11616-15-01 LIT-11616-16-34 LIT-11666-15-01

YFM660FSLIT-11616-17-14

YFM660FHSWL Grizzly 660 LIT-11626-17-14 YFM660FP YFM660FR LIT-11616-GZ-66 YFM660FPWetlands™ LIT-11616-15-01 LIT-11616-16-34 LIT-11666-15-01

YFM660FS LIT-11616-17-14

YFM660RS 660R Raptor LIT-11626-17-05 YFM660RN YFM660RP LIT-11616-RP-66 LIT-11666-17-05LIT-11616-14-21 LIT-11616-15-31

YFM660RLES 660R Raptor LIT-11626-17-05 YFM660RN YFM660RP LIT-11616-RP-66 LIT-11666-17-05Limited Edition - LIT-11616-14-21 LIT-11616-15-31Black

Model Owner’s Service Manual Supplements Compilation Manual Assembly Model Name Manual (Main) (Supplements Only) (Main & Supplements) Manual


ROUTE TO: SERVICE PARTS WARRANTY SALES PAGE 3 of 3

CATEGORY PUBLICATIONS PART NUMBER

2004 ATV Utility Accessory Brochure LIT-ATCAT-00-042004 Sport ATV Accessory Brochurre LIT-ATCAT-SP-042004 ATV Full Line Mini Brochure LIT-ATVMI-N1-042004 Sports ATVs Brochure LIT-11104-SP-RT2004 Utility ATVs Brochure LIT-11104-UT-ILTips and Practice Guide for the ATV Rider LIT-11626-15-49Ride Safe, Ride Smart Videotape VID-17299-00-00ATV Rally CD-ROM LIT-17299-CD-00ATV Warranty Statement* LIT-11790-002-03ATV Safety Alert LIT-17451-02-03Used ATV Safety Verification Form LIT-17299-01-2KY-12 Hang Tag (YFM80 models only) 4EM-2819R-00-00Y-6 Hang Tag (YFM50 models only) 5YF-2819R-00-00Utility Hang Tag 5KM-2819R-00-00Sport Hang Tag (660R Raptor, Banshee, Warrior, Blaster) 5LP-2819R-00-00General Hang Tag (all others) 5KM-2819R-00-00ATV Set-Up and Predelivery Checklist LIT-17161-01-2K2004 MCY/ATV/SxS Technical Update Book LIT-17500-00-042004 MCY/ATV/SxS Technical Update CD LIT-CDTEC-MS-04Parts System Handbook LIT-10080-07-04Warranty Labor Rate Change Request LIT-11791-02-02’95 ~ ’04 ATV Service Data Book LIT-SDATA-AT-002004 ATV Flat Rate Manual LIT-17750-00-04Warranty and Y.E.S. Handbook LIT-11760-00-03Y.E.S. Plan Highlights - Motorsports LIT-11580-00-05Y.E.S. Motorsports Sample Contract LIT-11580-00-38 Y.E.S. Registration Card LIT-11590-00-04Y.E.S. Used Unit Registration Card LIT-11580-00-19Y.E.S. Motorsports Used Hang Tag LIT-11580-00-40Y.E.S. Motorsports Hang Tag LIT-11580-00-16Y.E.S. Motorsports Brochure LIT-11580-00-36Y.E.S. Maintenance Log LIT-11580-00-03Y.E.S. Request to Cancel Form LIT-11580-00-10Y.E.S. Plan Lienholder Information LIT-11580-00-08Y.E.S. It Works Video VID-10660-00-78Y.E.S. Motorsports Poster LIT-11580-00-41

OTHER PUBLICATIONSOrder the following publications from Yamaha Parts and Accessories:

Consumer



Model Year Suffix Letter Chart

Model Year Suffix Letter

1987 T1988 U1989 W1990 A1991 B1992 D1993 E1994 F1995 G1996 H1997 J1998 K1999 L2000 M2001 N2002 P2003 R2004 S


YFM50S Raptor 50 49cc 5YF1 AA013-0000014YFM80WS Raptor 80 79cc 5TH8 AB02Y-0022092YFA-1S Breeze 124cc 5VJ4 AE013-0015823YFA-1SC Breeze (California Model) 124cc 5VJ5 AE01Y-0002636YFM125S Grizzly 125 124cc 1C51 AE02Y-0000013YFS200S Blaster 195cc 5VM3 AG023-0014092YFM25XS BearTracker 230cc 4XEL AG01Y-0103801YFM350S Raptor 350 348cc 5YT1 AH12Y-0000015YFM35FXS Wolverine 4WD 348cc 4KBX AH04Y-0015688YFM35XS Warrior 348cc 5NFB 3GD03-0039676YFM35XSC Warrior (California Model) 348cc 5NFC AH01Y-0007082YFZ350S Banshee 347cc 5FKP 3GG03-0049053YFZ350LES Banshee (Limited Edition) 347cc 5FKT 3GG03-0049053YFM35AS Bruin Auto 2WD 348cc 5WH1 AH10Y-0000101YFM35FAS Bruin Auto 4WD 348cc 5UH1 AH09Y-0000101YFM35FAHS Bruin Auto 4WD (Hunter Edition) 348cc 5UH3 AH11Y-0000101YFM40S Big Bear 400 2WD 386cc 5GWB AH08Y-0003401YFM40FS Big Bear 400 4WD 386cc 5FUE AH06Y-0047401YFM4AS Kodiak 400 2WD 401cc 5VH5 AJ08Y-0007802YFM4FAS Kodiak 400 4WD 401cc 5TE6 AJ07Y-0016301YFM4FAHS Kodiak 400 4WD (Hunter Edition) 401cc 5TEA AJ13Y-0000101YFM45FAS Kodiak 450 4WD 421cc 5ND6 AJ06Y-0015601YFM45FAHS Kodiak 450 4WD (Realtree Hardwoods® Hunter

Edition) 421cc 5NDC AJ12Y-0000101

YFZ450S YFZ450 439cc 5TG1 AJ11Y-0000026YFM660RS 660R Raptor 660cc 5LPF AM01Y-0045700 YFM660RLERS 660R Raptor (Limited Edition) 660cc 5LPJ AM01Y-0045700 YFM660FS Grizzly 660 4WD 660cc 5KMH AM03Y-0024941YFM660FHS Grizzly 660 4WD (Realtree Hardwoods® Hunter

Edition) 660cc 5KMM AM03Y-0024941

YFM660FHSWL Grizzly 660 4WD (Realtree Wetlands™ HunterEdition) 660cc 5KMN AM03Y-0024941

YFM660FLES Grizzly 660 4WD (Limited Edition) 660cc 5KMP AM03Y-0024941

ATV 5/21/04 AT2004-005


PAGE 1 of 1


The following is a comprehensive listing of Primary ID numbers for 2004 Yamaha ATVs. The frame num-ber of a unit contains the Primary ID for warranty purposes. Production started with the listed numbersbelow. For more Primary ID details, see Technical Bulletin AT97-006 or AT99-003. The Model Codeappears on a label on the ATV and is useful to help identify the model when contacting Yamaha Parts& Accessories. This code is also referenced with other model information at the beginning of the PartsList on CD-ROM.Model Model Name Displacement Model Code Starting PID No.


ATV 5/23/03 AT2003-002


PAGE 1 of 6



Color Rite Distribution Company11603 Groveland Ave.Whittier, CA 90604For Info (562) 947-9796Fax (562) 947-5087To ORDER, CALL: (800) 736-7980 E-Mail: [email protected] Site: www.color-rite.com.

When ordering, please provide Color Rite with the Year, Model, and Paint Code. Remember to providecall back information for your dealership (e.g., phone number / fax / e-mail).

A Model Application Guide providing detailed information by model year can be found at Color Rite’s webpage:

www.color-rite.com


For previous model year paint information, please refer to the following:● (’91~’99) Paint Reference Guide (P/N: LIT-10030-PC-99)● (’91~’99) Summer ’99 Paint Chart Reference Guide (P/N: LIT-10030-PC-2K)● (’99~’00) ATV Paint Reference Chart (Technical Bulletin AT2001-005)● (2001) ATV Paint Reference Chart (Technical Bulletin AT2001-003) ● (2002) ATV Paint Reference Chart (Technical Bulletin AT2001-009)

660 Grizzly 5KM8 Hunter Edition Body* N/AYFM660FHR (Realtree Hardwoods® Frame Yamaha Black 0033Realtree Hardwoods® Camo Camouflage) Front Bumper Low Gloss Black 0098Hunter Edition Carrier (F&R) Chijimi Black 00W0


660 Grizzly 5KMG Hunter Edition Body* N/AYFM660FHR-H (Advantage® Wetlands™ Frame Yamaha Black 0033 Realtree® Wetlands™ Camo Camouflage) Front Bumper Low Gloss Black 0098 Hunter Edition Carrier (F&R) Chijimi Black 00W0


660 Grizzly Limited Edition 5KMD Limited Edition Metallic Body Dark Gray Metallic A 0821 YFM660FRGY Titanium Frame Yamaha Black 0033

Front Bumper Low Gloss Black 0098 Carrier (F&R) Chijimi Black 00W0 Wheel Low Gloss Black 0098

660 Grizzly 5KMA Hunter Green Body* Pastel Deep Green 00K0 YFM660FR Frame Yamaha Black 0033


Beige Body* Dark Grayish Yellow Solid 1 0598 Frame Yamaha Black 0033Front Bumper Titanic Gray Metallic 00MACarrier (F&R) Chijimi Black 00W0Wheel No paint

Red Body* Romantique Rouge 00TRFrame Yamaha Black 0033Front Bumper Titanic Gray Metallic 00MACarrier (F&R) Chijimi Black 00W0Wheel No paint

Kodiak 450 A 4x4 Ultramatic 5ND5 Hunter Edition Body* N/AYFM45FAHR (Realtree Hardwoods® Frame Yamaha Black 0033Realtree Hardwoods® Camor Camouflage) Front Bumper Chijimi Black 00W0Hunter Edition Carrier (F&R) Chijimi Black 00W0


Kodiak 450 4X4 Ultramatic 5ND1 Hunter Green Body* Pastel Deep Green 00K0YFM45FAR Frame Yamaha Black 0033

Front Bumper Chijimi Black 00W0Carrier (F&R) Chijimi Black 00W0Wheel Titanic Gray Metallic 00MA

Beige Body* Dark Grayish Yellow Solid 1 0598 Frame Yamaha Black 0033Front Bumper Chijimi Black 00W0Carrier (F&R) Chijimi Black 00W0Wheel Titanic Gray Metallic 00MA

Red Body* Romantique Rouge 00TRFrame Yamaha Black 0033Front Bumper Chijimi Black 00W0Carrier (F&R) Chijimi Black 00W0Wheel Titanic Gray Metallic 00MA

Kodiak 400 4x4 Ultramatic 5TE5 Hunter Edition Body* N/AYFM4FAHR (Realtree Hardwoods® Frame Yamaha Black 0033Realtree Hardwoods® Camo Camouflage) Front Bumper Chijimi Black 00W0Hunter Edition Carrier (F&R) Chijimi Black 00W0





NOTE: When orderingpre-painted or plasticbody parts from the Parts Catalog, checkthe code next to the part number, andthis chart for colorverification.






PAGE 2 of 6

513556545187^5654

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51355187^5187^5654


UTILITY

(YB)(LGB)(WVB)(LGB)

(YB)(LGB)(WVB)(LGB)

(DGMA)(YB)(LGB)(WVB)(LGB)

(PDG)(YB)(TGM)(WVB)

(DNYS1)(YB)(TGM)(WVB)

(RTR)(YB)(TGM)(WVB)

(YB)(WVB)(WVB)(LGB)


(DNYS1)(YB)(WVB)(WVB)(TGM)


(YB)(WVB)(WVB)(LGB)

Kodiak 4X4 Ultramatic 5TE1 Hunter Green Body* Pastel Deep Green 00K0 YFM4FAR Frame Yamaha Black 0033


Beige Body* Dark Grayish Yellow Solid 1 0598 Frame Yamaha Black 0033Front Bumper Chijimi Black 00W0Carrier (F&R) Chijimi Black 00W0Wheel Low Gloss Black 0098

Red Body* Romantique Rouge 00TRFrame Yamaha Black 0033Front Bumper Chijimi Black 00W0Carrier (F&R) Chijimi Black 00W0Wheel Low Gloss Black 0098

Kodiak 400 Ultramatic 2WD 5VH1 Hunter Green Body* Pastel Deep Green 00K0YFM4AR Frame Yamaha Black 0033

Front Bumper Chijimi Black 00W0Carrier (F&R) Chijimi Black 00W0Wheel Low Gloss Black 0098

Beige Body* Dark Grayish Yellow Solid 1 0598 Frame Yamaha Black 0033Front Bumper Chijimi Black 00W0Carrier (F&R) Chijimi Black 00W0Wheel Low Gloss Black 0098

Red Body* Romantique Rouge 00TRFrame Yamaha Black 0033Front Bumper Chijimi Black 00W0Carrier (F&R) Chijimi Black 00W0Wheel Low Gloss Black 0098

Big Bear 400 4X4 5FUC Hunter Green Body* Pastel Deep Green 00K0YFM40FR Frame Yamaha Black 0033












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PAGE 3 of 6

UTILITY (CONT’D)


(DNYS1)(YB)(WVB)(WVB)(LGB)



(DNYS1)(YB)(WVB)(WVB)(LGB)





Big Bear 400 2WD 5GW9 Hunter Green Body* Pastel Deep Green 00K0 YFM400NR Frame Yamaha Black 0033




BearTracker 4XEH Hunter Green Body* Pastel Deep Green 00K0YFM250XR Frame Yamaha Black 0033




660R Raptor 5LP9 Team Yamaha Blue / YFM660RR White Body* Deep Purplish Blue Solid E 0583

Frame Deep Purplish Blue Metallic C 0564 Front Bumper Silver 0035Wheel (no paint)

Black / Body* Yamaha Black 0033Red Body* Romantique Rouge 00TR

Frame Silver 0035Front Bumper Silver 0035Wheel (no paint)

660R Raptor 5LPC Black Body* Yamaha Black 0033YFM660RLER (with Blue Flames) Frame Mat Black 2 0582(Limited Edition) Front Bumper Mat Black 2 0582

Wheel (no paint)

Black Body* Yamaha Black 0033(with Red Flames) Frame Mat Black 2 0582

Front Bumper Mat Black 2 0582Wheel (no paint)



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PAGE 4 of 6

SPORT

UTILITY (CONT’D)(PDG)(YB)(WVB)(WVB)(TGM)

(DNS1)(YB)(WVB)(WVB)(TGM)





(DPBSE)(DPBMC)(SL)

(YB)(RTR)(SL)(SL)

(YB)(MBL2)(MBL2)

(YB)(MBL2)(MBL2)

Banshee 5FKJ Team Yamaha Blue / YFZ350R White Body* Deep Purplish Blue Solid E 0583 (DPBSE)

Frame Silver 0035 (SL) Front Bumper Silver 0035 (SL) Wheel no paint

Black / Body* Yamaha Black 0033 (YB)Red Body* Romantique Rouge 00TR (RTR)

Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel no paint

Banshee 5FKM Yellow / Body* Light GreenishYellow Solid 3 0864 (LGYS3) YFZ350LER Black Body* Yamaha Black 0033 (YB)(Limited Edition) (with Flames) Frame Mat Black 2 0582 (MBL2)

Front Bumper Mat Black 2 0582 (MBL2)Wheel no paint

Wolverine 4X4 4KBV Team Yamaha Blue Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFM35FXR Frame Yamaha Black 0033 (YB)

Front Bumper Silver 0035 (SL)Carrier (R) Yamaha Black 0033 (YB)Wheel Silver 0035 (SL)

Black Body* Yamaha Black 0033 (YB)Frame Yamaha Black 0033 (YB)Front Bumper Yamaha Black 0033 (YB)Carrier (R) Yamaha Black 0033 (YB) Wheel Low Gloss Black 0098 (LGB)

Warrior Team Yamaha Blue / YFM35XR 5NF8 / White Body* Deep Purplish Blue Solid E 0583 (DPBSE)

5NF9 Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel no paint


Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel no paint

Blaster 5VM1 Team Yamaha Blue / YFS200R White Body* Deep Purplish Blue Solid E 0583 (DPBSE)

Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel Silver 0035 (SL)


Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel Silver 0035 (SL)

Breeze 5VJ1 / Team Yamaha Blue Body* Deep Purplish Blue Solid E 0583 (DPBSE)YFA1R / C 5VJ2 Frame Yamaha Black 0033 (YB)

Front Bumper Yamaha Black 0033 (YB)Wheel Silver 0035 (SL)

Hunter Green Body* Pastel Deep Green 00K0Frame Yamaha Black 0033 (YB)Front Bumper Yamaha Black 0033 (YB)Wheel Silver 0035 (SL)









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SPORT (CONT’D)

(PDG)

Raptor 80 5TH5 Team Yamaha Blue /YFM80WR White Body* Deep Purplish Blue Solid E 0583 (DPBSE)

Frame Yamaha Black 0033 (YB) Front Bumper Silver 0035 (SL) Wheel Silver 0035 (SL)


Frame Yamaha Black 0033 (YB)Front Bumper Silver 0035 (SL)Wheel Silver 0035 (SL)






Model codescan be usedto confirmthe modelyear of theunit. Color-Rite Paint Code Information:



5829513556165616

51355650513556165616


SPORT (CONT’D)

ROUTE TO: SERVICE PARTS WARRANTY SALES✓ ✓ ✓ ✓PAGE 6 of 6

ATV 3/04/03 AT2003-001


PAGE 1 of 3


This bulletin contains a comprehensive listing of Service Literature Part Numbers for 2003 models.Certain models will not have new literature if the prior year’s information is still current. Those literaturepart numbers will be listed, but “Same as . . .” will appear in the appropriate Manual column. The man-uals listed in the chart below can be ordered from Crestec Los Angeles, Inc. (Ph: 1-888-530-9446,FAX: 1-310-527-5853). Refer to Technical Bulletin AT2000-004 for more information. This bulletin alsolists other publications related to your dealership operation (see page 3), which can be ordered fromYamaha Parts and Accessories.

Owner’s Service AssemblyModel Model Name Manual Manual Supplement Manual

YFM80WR Raptor 80 LIT-11626-16-07 LIT-11616-YF-80 LIT-11616-15-38 LIT-11666-15-38Same as Same as Same as

YFM80W D~P YFM80W P YFM80W P

YFA1R Breeze LIT-11626-16-04 LIT-11616-YF-00 LIT-11616-15-08 LIT-11666-06-75Same as Same as Same as

YFA1 W~P YFA1 P YFA1 W~P

YFA1R(C) Breeze (Calif.) LIT-11626-16-04 LIT-11616-YF-00 LIT-11616-15-08 LIT-11666-06-75Same as Same as Same as

YFA1 W~P YFA1 P YFA1 W~P

YFS200R Blaster LIT-11626-16-37 LIT-11616-07-20 LIT-11616-16-37 LIT-11666-16-37LIT-11616-15-05

Same asYFS200 P

YFM250XR BearTracker LIT-11626-16-14 LIT-11616-12-01 LIT-11616-14-17 LIT-11666-12-01Same as Same as Same as

YFM250X L~P YFM250X N~P YFM250X L~PLIT-11616-15-03

Same asYFM250X P

YFM35FXR Wolverine LIT-11626-16-03 LIT-11616-FX-36 LIT-11616-14-02 LIT-11666-09-58Same as Same as Same as

YFM35FX G~P YFM35FX N~P YFM35FX G~PLIT-11616-15-07

Same asYFM35FX P

YFM35XR Warrior LIT-11626-16-08 LIT-11616-YM-37 LIT-11616-15-09 LIT-11666-08-60Same as Same as Same as

YFM35X A~P YFM35X P YFM35X E~P


PAGE 2 of 3

YFM35XR(C) Warrior (Calif.) LIT-11626-16-08 LIT11616-YM-37 LIT-11616-15-09 LIT-11666-08-60Same as Same as Same as

YFM35X A~P YFM35X P YFM35X E~P

YFZ350R Banshee LIT-11626-16-29 LIT-11616-YF-36 LIT-11616-15-04 LIT-11666-07-86Same as Same as Same as

YFZ350 T~P YFZ350 P YFZ350 B~P

YFZ350LER Banshee LIT-11626-16-29 LIT-11616-YF-36 LIT-11616-15-04 LIT-11666-07-86Limited Edition Same as Same as Same as

YFZ350 T~P YFZ350 P YFZ350 B~P

YFM4AR Kodiak 400 2WD LIT-11626-16-35 LIT-11616-16-02 LIT-11616-16-35 LIT-11666-16-35Ultramatic

YFM400NR Big Bear 400 2WD LIT-11626-16-12 LIT-11616-BB-2K LIT-11616-15-21 LIT-11666-13-34Same as Same as Same as

YFM400 M~P YFM400 P YFM400 M~P

YFM40FR Big Bear 4x4 LIT-11626-16-13 LIT-11616-BB-2K LIT-11616-15-22 LIT-11666-13-22Same as Same as Same as

YFM40F M~P YFM40F P YFM40F M~P

YFM4FAR Kodiak 4x4 LIT-11626-16-02 LIT-11616-16-02 LIT-11666-16-02Ultramatic

YFM4FAHR Kodiak 4x4 LIT-11626-16-02 LIT-11616-16-02 LIT-11666-16-02Hunter Ultramatic

YFM45FAR Kodiak 450 4x4 LIT-11626-16-01 LIT-11616-16-01 LIT-11666-16-01Ultramatic

YFM45FAHR Kodiak 450 4x4 LIT-11626-16-01 LIT-11616-16-01 LIT-11666-16-01Hunter Ultramatic

YFM660FR Grizzly 660 LIT-11626-16-34 LIT-11616-15-01 LIT-11616-16-34 LIT-11666-15-01Same as Same as

YFM660F P YFM660F P

YFM660FRGY Grizzly 660 LIT-11626-16-34 LIT-11616-15-01 LIT-11616-16-34 LIT-11666-15-01Limited Edition Same as Same as

YFM660F P YFM660F P

YFM66FHR Grizzly 660 Hunter LIT-11626-16-34 LIT-11616-15-01 LIT-11616-16-34 LIT-11666-15-01Same as Same as

YFM66FH P YFM66FH P

YFM660RR 660R Raptor LIT-11626-16-09 LIT-11616-14-21 LIT-11616-15-31 LIT-11666-14-21Same as Same as Same as

YFM660R N~ P YFM660R P YFM660R N~P

YFM660RLER 660R Raptor LIT-11626-16-09 LIT-11616-14-21 LIT-11616-15-31 LIT-11666-14-21Limited Edition - Same as Same as Same asBlack YFM660R N~P YFM660R P YFM660R N~P


ATV Warranty Statement* LIT-11790-02-86ATV Safety Alert LIT-17451-02-01Ride Safe, Ride Smart Videotape VID-17299-00-00ATV Rally CD-ROM LIT-17299-CD-00Used ATV Safety Verification Form LIT-17299-01-2KY-12 Hang Tag (Badger only) 2FJ-2819R-00-00Y-6 Hang Tag IHN-2819R-00-00Utility Hang Tag 3GH-2819R-00-00Sport Hang Tag (Raptor, Banshee, Warrior, Blaster) 3JM-2819R-00-00General Hang Tag (all others) 3FA-2819R-00-00Tips and Practice Guide for the ATV Rider LIT-11626-15-49ATV Set-Up and Predelivery Checklist LIT-17161-01-2K2003 ATV Flat Rate Manual LIT-17750-00-03ATV Technical Service Data (’99~’01) LIT-17571-SD-012002 Motorcycle/ATV Service Data Book LIT-SDATA-MC-ATWarranty and Y.E.S. Handbook LIT-11760-00-02Parts System Handbook LIT-10080-07-012003 ATV Accessory Brochure LIT-ATCAT-00-032003 ATV Full Line Mini Brochure LIT-ATVMI-N1-032003 Sports ATVs Brochure LIT-11103-SP-OR2003 Utility ATVs Brochure LIT-11103-UT-ILY.E.S. Plan Highlights - Motorsports LIT-11580-00-05Y.E.S. Sample Contract LIT-11580-00-38 Y.E.S. Registration Card LIT-11590-00-04Y.E.S. Used Hang Tag LIT-11580-00-40Y.E.S. Motorsports Hang Tag LIT-11580-00-16Y.E.S. Used Unit Registration Card LIT-11580-00-19Y.E.S. Motorsports Brochure LIT-11580-00-36Y.E.S. Maintenance Log LIT-11580-00-03Y.E.S. Request to Cancel Form LIT-11580-00-10Y.E.S. Plan Lienholder Information LIT-11580-00-08Y.E.S. It Works Video VID-10660-00-78

Other Publications Part Number

*The Limited Warranty Statement is also printed in each Owner’s Manual.

Order the following publications from Yamaha Parts and Accessories:

ROUTE TO: SERVICE PARTS WARRANTY SALES✓ ✓ ✓ ✓ PAGE 3 of 3


YFM80WR Raptor 80 79cc 5TH5 AB02Y-009110YFA-1R Breeze 124cc 5VJ1 AE013-011538YFA-1RC Breeze (California Model) 124cc 5VJ2 AE01Y-001876YFS200R Blaster 195cc 5VM1 AG023-000010YFM25XR BearTracker 230cc 4XEH AG01Y-091201YFZ350R Banshee 347cc 5FKJ 3GG03-038806YFZ350LER Banshee Special Edition 347cc 5FKM 3GG03-040522YFM35FXR Wolverine 4WD 348cc 4KBV AH04Y-011627YFM35XR Warrior 348cc 5NF8 3GD03-031103YFM35XRC Warrior (California Model) 348cc 5NF9 AH01Y-005632YFM40NR Big Bear 400 2WD 386cc 5GW9 AH08Y-000101YFM40FR Big Bear 400 4WD 386cc 5FUC AH06Y-034801YFM4AR Kodiak 400 2WD 401cc 5VH1 AJ08Y-000101YFM4FAR Kodiak 400 4WD 401cc 5TE1 AJ07Y-000101YFM4FHAR Kodiak 400 Hunter Edition 401cc 5TE5 AJ09Y-000101YFM45FAR Kodiak 450 421cc 5ND1 AJ06Y-000101YFM45FAHR Kodiak 450 Hunter Edition 421cc 5ND5 AJ10Y-000101 YFM660RR 660R Raptor 660cc 5LP9 AM01Y-022872 YFM660RLER 660R Raptor Limited Edition 660cc 5LPC AM01Y-027578YFM660FR Grizzly 660 660cc 5KMA AM03Y-000127YFM660FHR Grizzly 660 Hardwoods Hunter Edition 660cc 5KM8 AM03Y-000101YFM660FRGY Grizzly 660 Limited Edition 660cc 5KMD AM03Y-006985YFM66FHRWL Grizzly Wetlands Hunter Edition 660cc 5KMG AM03Y-016697

ATV 7/02/03 AT2003-003


PAGE 1 of 1


The following is a comprehensive listing of Primary ID numbers for 2003 Yamaha ATVs. The frame num-ber of a unit contains the Primary ID for warranty purposes. Production started with the listed numbersbelow. For more Primary ID details, see Technical Bulletin AT97-006 or AT99-003. The Model Codeappears on a label on the ATV and is useful to help identify the model when contacting Yamaha Parts& Accessories. This code is also referenced with other model information at the beginning of the PartsList on microfiche or CD-ROM.Model Model Name Displacement Model Code Starting PID No.*


* The Serial Number of the ATV is the last 6-digits of the VIN. When using the YDS (Yamaha Dealer System), you are requiredto add a “0” (zero) at the beginning of the 6-digits of the VIN. So if the correct Primary ID is 3GG03-038305, you would typein 3GG03-0038305 on YDS.

A good rule of thumb is if the computer won’t take a 6-digit serial number or if the paper form has room for 7-digits, make it a7-digit serial number with a zero in the first position.

ATV 8/02/01 AT2001-009


PAGE 1 of 5



Color Rite Distribution Company11603 Groveland Ave.Whittier, CA 90604For Info (562) 947-9796Fax (562) 947-5087To ORDER, CALL: (800) 736-7980 E-Mail: [email protected] Web Site: www.color-rite.com.

When ordering, please provide Color Rite with the Year, Model, and Paint Code. Remember to providecall back information for your dealership (e.g. phone number / fax / e-mail).

A Model Application Guide providing detailed information by model year can be found at Color Rite’s webpage:

www.color-rite.com

NOTE: The following paint chart is also very useful when ordering pre-painted and plastic body partsfrom the parts catalog. Paint codes are generally listed on the first page of the parts catalog and next tothe part number of the pre-painted or plastic body part. This chart can be used to confirm the color ofthe part you are ordering. The Model Code and starting V.I.N. numbers are also listed on the first pageof the parts catalog and can be used to confirm the model year of the ATV. The Sales color name maybe used for more than one paint color. Applicable Sales Color Codes have also been included in theSales Color Name column.

For previous model year paint information, please refer to the following:● (’91~’99) Paint Reference Guide (P/N: LIT-10030-PC-99)● (’91~’99) Summer ’99 Paint Chart Reference Guide (P/N: LIT-10030-PC-2K)● ’99~’00 ATV Paint Reference Chart (Technical Bulletin AT2001-005)● 2001 ATV Paint Reference Chart (Technical Bulletin AT2001-003)

"Grizzly 660 4X4" 5KM5 Hunter Edition Body* N/A(Hunter Edition) (RealTree Hardwoods®) Frame Yamaha Black 0033 (YB) YFM660FHP Front Bumper Low Gloss Black 0098 (LGB)

Carrier (F&R) Chijimi Black 00W0 (WVB) Wheel Low Gloss Black 0098 (LGB)

"Grizzly 660 4X4" 5KM1 Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) YFM660FP Frame Yamaha Black 0033 (YB)

Front Bumper Yamaha Black 0033 (YB) Carrier (F&R) Chijimi Black 00W0 (WVB) Wheel (no paint)

Beige (E) Body* Dark Grayish Yellow Solid 1 0598 (DNYS1) Frame Yamaha Black 0033 (YB) Front Bumper Yamaha Black 0033 (YB) Carrier (F&R) Chijimi Black 00W0 (WVB) Wheel (no paint)

Red (R) Body* Romantique Rouge 00TR (RTR) Frame Yamaha Black 0033 (YB) Front Bumper Yamaha Black 0033 (YB) Carrier (F&R) Chijimi Black 00W0 (WVB) Wheel (no paint)

"Grizzly 660 4X4" 5KM6 Limited Edition Silver Body Light Gray Metallic B 0698 (LNMB) YFM660FPS Frame Yamaha Black 0033 (YB)

Front Bumper Yamaha Black 0033 (YB) Carrier (F&R) Chijimi Black 00W0 (WVB) Wheel (no paint)

“660R Raptor" 5LP5 Team Yamaha Blue / YFM660RP White (L) Body* Deep Purplish Blue Solid E 0583 (DPBSE)

Frame Deep Purplish Blue Metallic C 0564 (DPBMC) Front Bumper Silver 0035 (SL) Wheel (no paint)

Black / Body* Yamaha Black 0033 (YB) White (W) Body* Radical White 00UJ (RW)

Frame Silver 0035 (SL) Front Bumper Silver 0035 (SL) Wheel (no paint)

"Kodiak 4X4" 5GHR Hunter Edition Body* N/A(Hunter Edition) (RealTree Hardwoods®) Frame Yamaha Black 0033 (YB) YFM4FAHP Front Bumper Low Gloss Black 0098 (LGB)

Carrier (F&R) Low Gloss Black 0098 (LGB) Wheel Low Gloss Black 0098 (LGB)

"Kodiak 4X4" 5GHK Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) YFM4FAP Frame Yamaha Black 0033 (YB)

Front Bumper Titanic Gray Metallic 00MA (TGM) Carrier (F&R) Yamaha Black 0033 (YB) Wheel Titanic Gray Metallic 00MA (TGM)

Beige (E) Body* Dark Grayish Yellow Solid 1 0598 (DNYS1) Frame Yamaha Black 0033 (YB) Front Bumper Titanic Gray Metallic 00MA (TGM) Carrier (F&R) Yamaha Black 0033 (YB) Wheel Titanic Gray Metallic 00MA (TGM)

Red (R) Body* Romantique Rouge 00TR (RTR) Frame Yamaha Black 0033 (YB) Front Bumper Titanic Gray Metallic 00MA (TGM) Carrier (F&R) Yamaha Black 0033 (YB) Wheel Titanic Gray Metallic 00MA (TGM)

2002 ATV Paint Reference Chart SALES PAINT YAMAHA COLOR RITE

MODEL MODEL CODE COLOR NAME COMPONENT COLOR NAME PAINT CODE PAINT CODE




Model codescan be used toconfirm themodel year ofthe unit.



NOTE: Stripes areavailable as graph-ic sets.

The letter in paren-thesis is the SalesColor Code - e.g., (L)

The Model Code andVIN numbers are alsolisted on the first page ofthe Parts Catalog andcan be used to confirmthe model year of theATV.

*Paint code for ref-erence only - Donot paint plasticbody (except

Grizzly 660 4x4Limited EditionSilver).

PAGE 2 of 5

5135 56545187^5654

5822513551355187^

5901513551355187^

5650513551355187^

5183513551355187^

582958155616

5135545756165616

5135565456545654

58225135586051355860

59015135586051355860

56505135586051355860

^ is not textured.

"Big Bear 400 4X4" 5FUA Hunter Edition Body* Pastel Deep Green 00K0 (PDG) (Hunter Edition) (RealTree X-tra® Brown Yamaha Black 0033 (YB) YFM40FHP Camo Seat) Front Bumper Titanic Gray Metallic 00MA (TGM)

Carrier (F&R) Yamaha Black 0033 (YB) Wheel Titanic Gray Metallic 00MA (TGM)

"Big Bear 400 4X4" 5FUA Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) YFM40FP Frame Yamaha Black 0033 (YB)



Red (R) Body* Romantique Rouge 00TR (RTR) Frame Yamaha Black 0033 (YB Front Bumper Titanic Gray Metallic 00MA (TGM) Carrier (F&R) Yamaha Black 0033 (YB) Wheel Titanic Gray Metallic 00MA (TGM)

"Big Bear 400" 5GW7 Hunter Edition Body* Pastel Deep Green 00K0 (PDG) (2WD) (RealTree X-tra® Brown Yamaha Black 0033 (YB) (Hunter Edition ) Camo Seat) Front Bumper Titanic Gray Metallic 00MA (TGM) YFM40HP Carrier (F&R) Yamaha Black 0033 (YB)

Wheel Titanic Gray Metallic 00MA (TGM)

"Big Bear 400" 5GW7 Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) (2WD) Frame Yamaha Black 0033 (YB) YFM40P Front Bumper Titanic Gray Metallic 00MA (TGM)

Carrier (F&R) Yamaha Black 0033 (YB) Wheel Titanic Gray Metallic 00MA (TGM)



"Wolverine 4X4" 4KBR Team Yamaha Blue (L) Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFM35FXP Frame Yamaha Black 0033 (YB)

Front Bumper Silver 0035 (SL) Carrier (F&R) Yamaha Black 0033 (YB) Wheel Silver 0035 (SL)

Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) Frame Yamaha Black 0033 (YB) Front Bumper Titanic Gray Metallic 00MA (TGM) Carrier (F&R) Yamaha Black 0033 (YB) Wheel Titanic Gray Metallic 00MA (TGM)








NOTE: Stripes areavailable as graph-ic sets.The letter in paren-

thesis is the SalesColor Code - e.g., (L)



PAGE 3 of 5

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Frame

Frame

"Warrior" Team Yamaha Blue / YFM350XP 5NF4 White (L) Body* Deep Purplish Blue Solid E 0583 (DPBSE) YFM35XPC 5NF5 Frame Silver 0035 (SL)

Front Bumper Silver 0035 (SL) Wheel no paint

Black / Body* Yamaha Black 0033 (YB) White (B) Body* Radical White 00UJ (RW)


"Banshee" 5FKE Team Yamaha Blue / YFZ350P White (L) Body* Deep Purplish Blue Solid E 0583 (DPBSE)




"BearTracker" 4XEE Hunter Edition Body* Pastel Deep Green 00K0 (PDG) YFM25XHP (RealTree X-tra® Brown Yamaha Black 0033 (YB)

Camo Seat) Front Bumper Titanic Gray Metallic 00MA (TGM) Carrier (F&R) Yamaha Black 0033 (YB) Wheel Titanic Gray Metallic 00MA (TGM)

"BearTracker" 4XEE Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) YFM25XP Frame Yamaha Black 0033 (YB)




"Blaster" 5KJ7 Team Yamaha Blue /YFS200P White (L) Body* Deep Purplish Blue Solid E 0583 (DPBSE)

Frame Silver 0035 (SL) Front Bumper Silver 0035 (SL) Wheel Silver 0035 (SL)


Frame Silver 0035 (SL) Front Bumper Silver 0035 (SL) Wheel Silver 0035 (SL)












PAGE 4 of 5

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Frame

“Breeze” 3FAW / 3FAX Black / Body* Yamaha Black 0033 (YB) YFA1P / C White Body* Radical White 00UJ (RW)

Frame Yamaha Black 0033 (YB) Front Bumper Yamaha Black 0033 (YB) Wheel Silver 0035 (SL)

“Raptor 80” 5TH1 Team Yamaha Blue /YFM80RPL White Body* Deep Purplish Blue Solid E 0583 (DPBSE)

Frame Yamaha Black 0033 (YB) Front Bumper Silver 0035 (SL) Wheel Silver 0035 (SL)

ROUTE TO: SERVICE PARTS WARRANTY SALES✓ ✓ ✓ ✓ PAGE 5 of 5







Color-Rite Paint Code Iinformation:1000 series codes are base coats.5000 series codes are color coats.All color coats must be clear coated.Use low gloss clear for low gloss paint.





51355457513551355616

5829513556165616

ATV 3/27/02 AT2002-008A


PAGE 1 of 2


This bulletin contains a comprehensive listing of Service Literature Part Numbers for 2002 models.Certain models will not have new literature if the prior year’s information is still current. Those literaturepart numbers will be listed, but “Same as . . .” will appear in the appropriate Manual column. The man-uals listed in the chart below can be ordered from Crestec Los Angeles, Inc. (Ph: 1-888-530-9446, FAX:1-310-527-5853). Refer to Technical Bulletin AT2000-004 for more information. This bulletin also listsother publications related to your dealership operation (see page 2), which can be ordered from YamahaParts and Accessories.


YFM80WP Raptor 80 LIT-11626-15-38 LIT-11616-YF-80 LIT-11616-15-38 LIT-11666-15-38

YFA1P Breeze LIT-11626-15-08 LIT-11616-YF-00 LIT-11616-15-08 LIT-11666-06-75Same as Same as

YFA1 W~N YFA1 W~N

YFA1P(C) Breeze (Calif.) LIT-11626-15-08 LIT-11616-YF-00 LIT-11616-15-08 LIT-11666-06-75Same as Same as

YFA1 W~N YFA1 W~N

YFS200P Blaster LIT-11626-15-05 LIT-11616-07-20 LIT-11616-15-05 LIT-11666-07-20Same as Same as

YFS200 U~N YFS200 A~N

YFM250XP BearTracker LIT-11626-15-03 LIT-11616-12-01 LIT-11616-15-03 LIT-11666-12-01Same as LIT-11616-14-17 Same as

YFM250X L~N YFM250X L~N

YFM350FXP Wolverine LIT-11626-15-07 LIT-11616-FX-36 LIT-11616-15-07 LIT-11666-09-58Same as Same as

YFM350FX G~N YFM350FX G~N

YFM350XP Warrior LIT-11626-15-09 LIT-11616-YM-37 LIT-11616-15-09 LIT-11666-08-60Same as Same as

YFM350X A~N YFM350X E~N

YFM350XP(C) Warrior (Calif.) LIT-11626-15-09 LIT11616-YM-37 LIT-11616-15-09 LIT-11666-08-60Same as Same as

YFM350X A~N YFM350X E~N

YFZ350P Banshee LIT-11626-15-04 LIT-11616-YF-36 LIT-11616-15-04 LIT-11666-07-86Same as same as

YFZ350 T~N YFZ350 B~N

Effective 6/25/02 this Technical Bulletin replaces AT2002-0008; please remove and destroy AT2002-008. Denotes a change in the original Technical Bulletin.

PAGE 2 of 2


YFM400P Big Bear 2WD LIT-11626-15-21 LIT-11616-BB-2K LIT-11616-15-21 LIT-11666-13-34Same as Same as

YFM400 M~N YFM400 M~N

YFM400FP Big Bear 4WD LIT-11626-15-22 LIT-11616-BB-2K LIT-11616-15-22 LIT-11666-13-22Same as Same as

YFM400FW M~N YFM400FW M~N

YFM400FAP Kodiak 4WD LIT-11626-15-19 LIT-11616-KD-2K LIT-11616-15-19 LIT-11666-13-21Same as Same as

YFM400FWA M~N YFM400FWA M~N

YFM400FHAP Kodiak 4WD LIT-11626-15-19 LIT-11616-KD-2K LIT-11616-15-19 LIT-11666-13-21Hunter Same aa Same as

YFM400FWHA M~N YFM400FWHA M~N

YFM660FAP Grizzly 660 LIT-11626-15-01 LIT-11616-15-01 LIT-11666-15-01YFM660FHAP Grizzly 660 Hunter LIT-11626-15-01 LIT-11616-15-01 LIT-11666-15-01YFM660FSAP Grizzly 660 Silver LIT-11626-15-01 LIT-11616-15-01 LIT-11666-15-01YFM660RP 660R Raptor LIT-11626-15-31 LIT-11616-14-21 LIT-11616-15-31 LIT-11666-14-21

Same as Same asYFM660R N YFM660R N

YFM660RP-B 660R Raptor LIT-11626-15-31 LIT-11616-14-21 LIT-11616-15-31 LIT-11666-14-21Limited Edition - Same as Same asBlack YFM660R N YFM660R N

ATV Warranty Statement* LIT-11790-02-86ATV Safety Alert LIT-17451-01-01Ride Safe, Ride Smart Videotape VID-17299-00-00ATV Rally CD-ROM LIT-17299-CD-00Used ATV Safety Verification Form LIT-17299-01-2KY-12 Hang Tag (Badger only) 2FJ-2819R-00-00Sport Hang Tag (Raptor, Banshee, Warrior, Blaster) 3JM-2819R-00-00General Hang Tag (all others) 3FA-2819R-00-00Tips and Practice Guide for the ATV Rider LIT-11626-15-49ATV Set-Up and Predelivery Checklist LIT-17161-01-2K2002 ATV Flat Rate Manual LIT-17750-00-02ATV Technical Service Data (’99~’01) LIT-17571-SD-01Motorcycle/ATV Service Data Binder LIT-SDATA-MC-ATY.E.S. Plan Highlights LIT-11580-00-05Y.E.S. Sample Contract LIT-11580-00-27 Warranty and Y.E.S. Handbook LIT-11760-00-02Parts System Handbook LIT-10080-07-012002 ATV Accessory Brochure LIT-ATCAT-00-022002 ATV Full Line Mini Brochure LIT-ATVMI-N1-022002 Sports ATVs Brochure LIT-11102-SP-OR2002 Utility ATVs Brochure LIT-11102-UT-IL






YFM80WP Raptor 80 79cc 5TH1 AB02Y-000032YFA-1P Breeze 124cc 3FAW AE013-007350YFA-1PC Breeze (California Model) 124cc 3FAX AE01Y-001326YFS200P Blaster 195cc 5KJ7 3JM03-039885YFM25XP BearTracker 230cc 4XEE AG01Y-072601YFM25XHP BearTracker Hunter Edition 230cc 4XEE AG01Y-075350YFZ350P Banshee 347cc 5FKE 3GG03-028762YFM35FXP Wolverine 348cc 4KBR AH04Y-009652YFM35XP Warrior 348cc 5NF4 3GD03-018702YFM350XPC Warrior (California Model) 348cc 5NF5 AH01Y-004072YFM40P Big Bear 2WD 386cc 5GW7 AH08Y-017702YFM40HP Big Bear 2WD Hunter Edition 386cc 5GW7 AH08Y-019549YFM40FP Big Bear 4WD 386cc 5FUA AH06Y-016201YFM40FHP Big Bear 4WD Hunter Edition 386cc 5FUA AH06Y-020101YFM4FAP Kodiak 4WD 401cc 5GHK AJ03Y-026912YFM4FHAP Kodiak Hunter Edition 401cc 5GHR AJ03Y-027392YFM660RP 660R Raptor 660cc 5LP5 AM01Y-003061YFM660RPB 660R Black Raptor 660cc 5LP8 AM01-015340YFM660FP Grizzly 660 660cc 5KM1 AM02Y-000030YFM660FHP Grizzly 660 Hunter Edition 660cc 5KM5 AM02Y-002030YFM660FPS Grizzly 660 Limited Edition Silver 660cc 5KM6 AM02Y-010957

ATV 6/19/02 AT2002-012


PAGE 1 of 1


The following is a comprehensive listing of Primary ID numbers for 2002 Yamaha ATV’s. The frame num-ber of a unit contains the Primary ID for warranty purposes. Production started with the listed numbersbelow. For more Primary ID details, see Technical Bulletin AT97-006 or AT99-003. The Model Codeappears on a label on the ATV and is useful to help identify the model when contacting Yamaha Parts& Accessories. This code is also referenced with other model information at the beginning of the PartsList on microfiche or CD-ROM.Model Model Name Displacement Model Code Starting PID No.*


* The Serial Number of the ATV is the last 6-digits of the VIN, but Yamaha has just introduced another twist if you use YDS (theYamaha Dealer System via the Internet) to do your warranty registrations and warranty claims, or use YCS Online functions.Yamaha computer systems now require a serial number that is seven numbers long.

Fortunately, this is easy to do. Just put a “0” (zero) at the beginning of the last 6-digits of the VIN - and it’s always a “0,” no mat-ter what other characters are in the VIN. So if the correct Primary ID is 3GG03-000353, you would type in 3GG030000353 onYDS (or with any YCS Online functions).

A good rule of thumb is if the computer won’t take a 6-digit serial number or if the paper form has room for 7-digits, make it a7-digit serial number with a zero in the first position.

ATV 2/14/01 AT2001-003


This bulletin provides paint identification and ordering information for 2001-model ATVs. All ATV paintmay be ordered through Color Rite:

National Sales Office11603 Groveland Ave.Whittier, CA 90604For Info (562) 947-9796Fax (562) 947-5087To ORDER, CALL (800) 736-7980 orE-Mail: [email protected]

When ordering, please provide Color Rite with the Year, Model, and Paint Code, and provide call-backinformation for your dealership (e.g., name, phone and/or fax number, e-mail address, etc.)

For 1999 and earlier models, use the Paint Chart Reference Guide (LIT-10030-PC-99) and the Summer’99 Paint Chart Reference Guide (LIT-10030-PC-2K). A Model Application Guide providing detailed infor-mation, by model year, can also be found on Color Rite’s web page: www.color-rite.com.

PAGE 1 of 5


Model Model ATV Color Component Paint Color Yamaha Paint Color-Rite PaintCode Name Name Code Code

YFM660RN/C 5LP1 / 5LP3 Team Yamaha Blue / (Raptor) White (L)

Body* Deep Purplish Blue Solid E 0583 (DPBSE)Frame Deep Purplish Blue Metallic C 0564 (DPBMC)Front Bumper Silver 0035 (SL)Wheel (No Paint)

Black / White (W)Body* Radical White 00UJ (RW)Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel (No Paint)

YFM600FAHN 5GTK Hunter Edition (Grizzly 4X4) (Realtree® X-tra™)

Body* N/A N/AFrame Yamaha Black 0033 (YB)Front Bumper Low Gloss Black 0098 (LGB)Wheel Low Gloss Black 0098 (LGB)

YFM600FAN 5GTE Hunter Green (GR)(Grizzly 4X4) Body* Pastel Deep Green 00K0 (PDG)

Frame Yamaha Black 0033 (YB)Front Bumper Titanic Gray Metallic 00MA (TGM)Wheel Titanic Gray Metallic 00MA (TGM)

Beige (E)Body* Dark Grayish Yellow Solid 1 0598 (DNYS1)Frame Yamaha Black 0033 (YB)Front Bumper Titanic Gray Metallic 00MA (TGM)Wheel Titanic Gray Metallic 00MA (TGM)

Red (R)Body* Romantique Rouge 00TR (RTR)Frame Yamaha Black 0033 (YB)Front Bumper Titanic Gray Metallic 00MA (TGM)Wheel Titanic Gray Metallic 00MA (TGM)

YFM400AN 5HA7 Hunter Green (GR)(Kodiak 2WD) Body* Pastel Deep Green 00K0 (PDG)




YFM400FAHN 5GHF Hunter Edition (Kodiak 4X4) (Realtree® X-tra™)

Body* N/A N/AFrame Yamaha Black 0033 (YB)Front Bumper Low Gloss Black 0098 (LGB)Wheel Low Gloss Black 0098 (LGB)

(C) Designates ATV Color Name * Paint code for ^ Paint is in the California model is for unit color reference only - Do process of

identification. not paint plastic being body. formulated -

Contact Color-Rite for base

Color-Rite paint code information: coat information.NOTE: U = UrethaneWhen ordering pre-painted parts from the parts catalog, check the first L = Lacquerpage of the parts list (microfiche or CD-ROM), the code next to the part, UL = Urethane or Lacquerand this chart for color verification. 1000 series codes are base coats

5000 series codes are color coatsAll color coats must be clear coated

PAGE 2 of 5

5829U5815U5616U

5457UL5616U5616U

N/A5135UL5654U5654U

5822U5135UL5860U5860U

5901U5135UL5860U5860U

5650U5135UL5860U5860U

5822U5135UL5860U5860U

5901U5135UL5860U5860U

5650U5135UL5860U5860U

N/A5135UL5654U5654U

2001 ATV Paint Reference Chart


YFM400FAN 5GH9 Hunter Green (GR)(Kodiak 4X4) Body* Pastel Deep Green 00K0 (PDG)




YFM400FHN 5FU9 Hunter Green(Big Bear 4X4 (Realtree® X-tra™ Seat) Body* Pastel Deep Green 00K0 (PDG)w/ Camo Seat) Frame Yamaha Black 0033 (YB)

Front Bumper Titanic Gray Metallic 00MA (TGM)Wheel Titanic Gray Metallic 00MA (TGM)

YFM400FN 5FU6 Hunter Green (GR)(Big Bear 4X4) Body* Pastel Deep Green 00K0 (PDG)




YFM400HN 5GW4 Hunter Green(Big Bear 2WD (Realtree® X-tra™ Seat) Body* Pastel Deep Green 00K0 (PDG)w/ Camo Seat) Frame Yamaha Black 0033 (YB)


YFM400N 5GW4 Hunter Green (GR)(Big Bear 2WD) Body* Pastel Deep Green 00K0 (PDG)




PAGE 3 of 5

5822U5135UL5860U5860U

5901U5135UL5860U5860U

5650U5135UL5860U5860U

5822U5135UL5860U5860U

5822U5135UL5860U5860U

5901U5135UL5860U5860U

5650U5135UL5860U5860U

5822U5135UL5860U5860U

5822U5135UL5860U5860U

5901U5135UL5860U5860U

5650U5135UL5860U5860U








YFM350FXN 4KBM Team Yamaha Blue / (Wolverine 4X4) White (L)

Body* Deep Purplish Blue Solid E 0583 (DPBSE)Frame Yamaha Black 0033 (YB)Front Bumper Silver 0035 (SL)Wheel Silver 0035 (SL)

Hunter Green (GR)Body* Pastel Deep Green 00K0 (PDG)Frame Yamaha Black 0033 (YB)Front Bumper Titanic Gray Metallic 00MA (TGM)Wheel Titanic Gray Metallic 00MA (TGM)

YFZ350N 5FKA Team Yamaha Blue / (Banshee) White (L)

Body* Deep Purplish Blue Solid E 0583 (DPBSE)Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL) 5616UWheel (no paint)

Black / White (W)Body* Radical White 00UJ (RW)Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel (no paint)

YFM350XN/C 3GDY / 5FN1 Team Yamaha Blue / (Warrior) White (L)

Body* Deep Purplish Blue Solid E 0583 (DPBSE)Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel (no paint)

Black / White (W)Body* Radical White 00UJ (RW)Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel (no paint)

YFM250XHN 4XEA Hunter Green(BearTracker (w/ Realtree® X-tra™ Seat) Body* Pastel Deep Green 00K0 (PDG)w/ Camo Seat) Frame Yamaha Black 0033 (YB)


YFM250XN 4XEA Hunter Green (GR)(BearTracker) Body* Pastel Deep Green 00K0 (PDG)




YFS200N 5KJ4 Team Yamaha Blue / (Blaster) White (L)

Body* Deep Purplish Blue Solid E 0583 (DPBSE)Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel Silver 0035 (SL)

Black / White (W)Body* Radical White 00UJ (RW)Frame Silver 0035 (SL)Front Bumper Silver 0035 (SL)Wheel Silver 0035 (SL)

5829U5135UL5616U5616U

5822U5135UL5860U5860U

5829U5616U

5457UL5616U5616U

5829U5616U5616U

5457UL5616U5616U

5822U5135UL5860U5860U

5822U5135UL5860U5860U

5901U5135UL5860U5860U

5650U5135UL5860U5860U

5829U5616U5616U5616U

5457UL5616U5616U5616U






PAGE 4 of 5



YFA1N/C 3FAT / 3FAU Black / White (W)(Breeze) Body* Radical White 00UJ (RW)

Frame Yamaha Black 0033 (YB)Front Bumper Yamaha Black 0033 (YB)Wheel Silver 0035 (SL)

YFM80HN 4EMX Hunter Green(Badger (Realtree® X-tra™ Seat) Body* Pastel Deep Green 00K0 (PDG)w/ Camo Seat) Frame Yamaha Black 0033 (YB)

Front Bumper Yamaha Black 0033 (YB)Wheel Yamaha Black 0033 (YB)

YFM80N/C 4EMX / 4EMY Team Yamaha Blue / (Badger) White (L)

Body* Deep Purplish Blue Solid E 0583 (DPBSE)Frame Yamaha Black 0033 (YB)Front Bumper Yamaha Black 0033 (YB)Wheel Silver 0035 (SL)


5457UL5135UL5135UL5616U

5822U5135UL5135UL5135UL

5829U5135UL5135UL5616U

PAGE 5 of 5







“Badger” 79 LIT-11626-14-04 LIT-11666-08-19 LIT-11616-YF-80YFM80N Same as Same as

YFM80 D~M YFM80 D~M

“Badger Realtree 79 LIT-11626-14-04 LIT-11666-08-19 LIT-11616-YF-80Hunter” Same as Same asYFM80HN YFM80 D~M YFM80 D~M

“Badger” (Calif.) 79 LIT-11626-14-04 LIT-11666-08-19 LIT-11616-YF-80YFM80N(C) Same as Same as

YFM80 D~M YFM80 D~M

“Breeze” 124 LIT-11626-14-03 LIT-11666-06-75 LIT-11616-YF-00YFA1N Same as Same as

YFA1 W~M YFA1M

“Breeze” (Calif.) 124 LIT-11626-14-03 LIT-11666-06-75 LIT-11616-YF-00YFA1N(C) Same as Same as

YFA1W C~M(C) YFA1M(C)

“Blaster” 195 LIT-11626-14-09 LIT-11666-07-20 LIT-11616-07-20YFS200N Same as Same as

YFS200 A~M YFS200 U~M

“Bear Tracker” 229.6 LIT-11626-14-17 LIT-11666-12-01 LIT-11616-12-01YFM250XN Same as LIT-11616-14-17

YFM250X L~M (Supplement)Same as

YFM250X L~M

2001 MODELSATV SERVICE LITERATURE


ATV 12/18/00 AT2000-013

PAGE 1 of 3

The following is a comprehensive listing of service literature part numbers for 2001 Yamaha ATV’s. If theservice literature used in prior years is still current, the literature part number will still be listed, but “Sameas . . .” will appear in the appropriate Manual column.

These manuals may be ordered from Crestec Los Angeles, Inc. (ph: 1-888-530-9446). Refer toTechnical Bulletin AT2000-005 for more information.

Actual Owner’s Assembly ServiceModel Displacement Manual Manual Manual

“Bear Tracker 229.6 LIT-11626-14-17 LIT-11666-12-01 LIT-11616-12-01Realtree Hunter” Same as LIT-11616-14-17YFM250XHN YFM250X L~M (Supplement)

Same asYFM250X L~M

“Wolverine” 348 LIT-11626-14-02 LIT-11666-09-58 LIT-11616-FX-36YFM350FXN Same as Same as

YFM350FX E~M YFM350FX G~M

“Warrior” 348 LIT-11626-14-10 LIT-11666-08-60 LIT-11616-YM-37YFM350XN Same as Same as

YFM350X E~M YFM350X A~M

“Warrior” (Calif.) 348 LIT-11626-14-10 LIT-11666-08-60 LIT-11616-YM-37YFM350XNC Same as Same as

YFM350X E~MC YFM350X A~M

“Banshee” 347 LIT-11626-14-08 LIT-11666-07-86 LIT-11616-YF-36YFZ350N Same as Same as

YFZ350 B~M YFZ350 T~M

“Big Bear” 2WD 386 LIT-11626-14--22 LIT-11666-13-34 LIT-11616-BB-2KYFM400N Same as Same as

YFM400NM YFM400FWNM

“Big Bear 2WD 386 LIT-11626-14--22 LIT-11666-13-34 LIT-11616-BB-2KRealtree Hunter” Same as Same as YFM400HN YFM400NM YFM400FWNM

“Big Bear” 4WD 386 LIT-11626-14-11 LIT-11666-13-22 LIT-11616-BB-2KYFM400FN Same as Same as

YFM400FWNM YFM400FWNM

“Big Bear - 4WD 386 LIT-11626-14-11 LIT-11666-13-22 LIT-11616-BB-2KRealtree Hunter “ Same as Same asYFM400FHN YFM400FWNM YFM400FWNM

“Kodiak” 2WD 386 LIT-11626-14-07 LIT-11666-13-39 LIT-11616-KD-2KYFM400AN Same as

YFM400AM

“Kodiak - 4WD” 386 LIT-11626-14-05 LIT-11666-13-21 LIT-11616-13-21YFM400FAN Same as Same as

YFM400FAM YFM400FAM

“Kodiak - 4WD 386 LIT-11626-14-05 LIT-11666-13-21 LIT-11616-13-21Realtree Hunter” Same as Same asYFM400FAHN YFM400FAHM YFM400FAHM

“Grizzly” 595 LIT-11626-14-06 LIT-11666-11-21 LIT-11616-FW-00YFM600FN Same as

YFM600FWAM

“Grizzly Realtree Hunter” 595 LIT-11626-14-06 LIT-11666-11-21 LIT-11616-FW-00YFM600FHN Same as

YFM600FWAM

“Raptor” 660 LIT-11626-14-21 LIT-11666-14-21 LIT-11616-14-21YFM660RN

“Raptor” (Calif.) 660 LIT-11626-14-21 LIT-11666-14-21 LIT-11616-14-21YFM660RNC

PAGE 2 of 3



PAGE 3 of 3ROUTE TO: SERVICE PARTS WARRANTY SALES

ATV Warranty Statement* LIT-11790-02-86ATV Safety Alert LIT-17451-00-99Ride Safe, Ride Smart Videotape VID-17299-00-00ATV Rally CD-ROM LIT-17299-CD-00Used ATV Safety Verification Form LIT-17299-01-2KY-12 Hang Tag (Badger only) 2FJ-2819R-00-00Sport Hang Tag (Raptor, Banshee, Warrior, Blaster) 3JM-2819R-00-96General Hang Tag (all others) 3FA-2819R-00-00Tips and Practice Guide for the ATV Rider LIT-17750-00-2KATV Set-Up and Predelivery Checklist LIT-17161-01-2K2000 ATV Flat Rate Manual LIT-17750-00-2KATV Technical Service Data (1998, 1999, 2000) LIT-17571-SD-2KY.E.S. Plan Highlights LIT-11580-00-05Sample Y.E.S. Contract LIT-11580-00-27 Warranty and Y.E.S. Handbook LIT-11760-00-95Parts System Handbook LIT-10080-07-01




ATV 10/17/00 AT2000-010


The following is a comprehensive listing of Primary I.D. numbers for 2001 Yamaha ATV’s. The framenumbers of a unit contains the Primary I.D. for warranty purposes. Because the engine number maynot match the frame number, be sure to use the frame number in all warranty documents. Productionstarted with the listed numbers below. For more Primary I.D. details, see Technical Bulletin AT97-006or AT99-003. The Model Code appears on a label on the ATV and is useful to help identify the modelwhen contacting Yamaha Parts & Accessories. This code is also referenced with other model infor-mation at the beginning of the Parts List on microfiche or CD-ROM.

PAGE 1 of 1ROUTE TO: SERVICE PARTS WARRANTY SALES

Model Model Name Displacement Model Code Starting PID No.YFM80N Badger 79cc 4EMX AB013-000004YFM80NC Badger, CA 79cc 4EMY AB01Y-000402YFM80HN Badger Realtree Hunter 79cc 4EMX AB013-000004YFA-1N Breeze 124cc 3FAT AE013-000002YFA-1NC Breeze, CA 124cc 3FAU AE01Y-000601YFS200N Blaster 195cc 5KJ4 3JM03-019348YFM25XN Bear Tracker 230cc 4XEA AG01Y-047201YFM25XHN Bear Tracker Realtree Hunter 230cc 4XEA AG01Y-047201YFZ350N Banshee 347cc 5FKA 3GG03-014443YFM35FXN Wolverine 348cc 4KBM AH04Y-000756YFM35XN Warrior 348cc 3GDY 3GD03-000006YFM350XNC Warrior, CA 348cc 5NF1 AH01Y-002872YFM40N Big Bear 2WD 386cc 5GW4 AH08Y-009501YFM40HN Big Bear 2WD Realtree Hunter 386cc 5GW4 AH08Y-009501YFM40FN Big Bear 4WD 386cc 5FU6 AH06Y-000101YFM40FHN Big Bear 4WD Realtree Hunter 386cc 5FU9 AH06Y-403101YFM400AN Kodiak 2WD 401cc 5HA7 AJ04Y-000351YFM4FAN Kodiak 4WD 401cc 5GH9 AJ03Y-001162YFM4FAHN Kodiak Realtree Hunter 401cc 5GHF AJ03Y-007257YFM600FN Grizzly 595cc 5GTE AJ02Y-001510YFM600FHN Grizzly Realtree Hunter 595cc 5GTK AJ02Y-010713YFM660RN Raptor 660cc 5lLP1 AM013-000052YFM660RNC Raptor, CA 660cc 5LP3 AM013-000002

ATV 6/29/01 AT2001-005

’99 ~ ’00 MODELSATV Paint Reference Charts

PAGE 1 of 5


This bulletin contains information regarding paint color codes for 1999 and 2000 model ATVs. The 1999information has updates or corrections to the references contained in the Summer 1999 Paint ChartReference Guide (LIT-10030-PC-2K).

For easy reference, the 2000 information includes the color name used in sales literature and the color-code designator used in the model name. Note that the Sales color names may be used for more thanone actual color. The 2000-model information also includes paint colors for frames, bumpers, andwheels, where applicable.

All paint may be ordered through Color Rite:

Color Rite Distribution Company11603 Groveland Ave.Whittier, CA 90604For info (562) 947-9796Fax (562) 947-5087To ORDER, CALL (800) 736-7980Web Site: www.color-rite.comE-mail: [email protected]

When ordering, please provide Color Rite with the Year, Model, and Paint Code. Remember to providecall-back information for your dealership (e.g., name, phone and/or fax number, e-mail address, etc.).

A Model Application Guide providing detailed information by model year, can be found at Color Rite’sweb page: www.color-rite.com.

NOTE: The following paint charts are also useful when ordering pre-painted parts from the PartsCatalog. Paint codes are generally listed on the first page of the Parts catalog and next to the part num-ber of the pre-painted or plastic body part. These charts can be used to confirm the color of the part youare ordering. The Sales Color Name may be used for more than one paint color. The Sales Color Codeshave been included in the Color Name column in the year 2000 chart.

ATV - 1999

Component Abbre- ColorModel Description Color Paint Name viation Code*YFM600FL/C Beige Dark Grayish Yellow Solid 1 DNYS1 598Grizzly Green Pastel Deep Green PDG 0K0

Red Romantique Rouge RTR 0TRYFM400FL/C Green Pastel Deep Green PDG 0K0Kodiak Red Romantique Rouge RTR 0TRYFM350FXL/C Green Pastel Deep Green PDG 0K0Wolverine Blue Deep Purplish Blue Solid E DPBSE 583YFM350FHL/C Hunter Green Pastel Deep Green PDG 0K0Big Bear 4WD(Hunter Edition)YFM350FL/C Beige Dark GrayishYellow Solid1 DNYS1 598Big Bear 4WD Green Pastel Deep Green PDG 0K0

Red Romantique Rouge RTR 0TRYFB250FL Green Pastel Deep Green PDG 0K0Timberwolf 4WDYFM350UL/C Beige Dark Grayish Yellow Solid 1 DNYS1 598Big Bear 2WD Green Pastel Deep Green PDG 0K0

Red Romantique Rouge RTR 0TRYFM250XL/C Beige Dark Grayish Yellow Solid 1 DNYS1 598BearTracker Green Pastel Deep Green PDG 0K0

Red Romantique Rouge RTR 0TRYFA1L White Radical White RW 0UJBreezeYFM80L White Radical White RW 0UJBadgerYFZ350L Blue Deep Purplish Blue Solid E 583Banshee Red Romantique Rouge RTR 0TRYFM350XL/C Dark Gray Low Gloss Gray LGG OT2Warrior White Radical White RW 0UJYFS200L Blue Deep Purplish Blue Solid E DPBSE 583Blaster White Radical White RW 0UJ

Paint Chart Reference Guide

PAGE 2 of 5

C - Designates *The Sales Color Name California Model is for unit color identifi-

cation. The Sales Color Name may be used for more than one paint color.

NOTE: When orderingpre-painted or plasticbody parts from the Parts Catalog, check .the first page of the parts list, the code next to the part number, andthis chart for colorverification.

*Paint code for referenceonly - Do notpaint plastic body parts.

*

’99~’00 ATV Paint Reference Chart

YFM600FHM / C 5GT9 / 5GTA Hunter Green Body* Pastel Deep Green (PDG) 5822(Grizzly 4WD ) (w/ Realtree X-tra® Seat) Yamaha Black 0033 (YB) 5135(w/ Camo Seat) Front Bumper Low Gloss Black 0098 (LGB) 5654

Wheel Mat Black 2 0582 (MBL2) 5988

YFM600FM / C 5GT6 / 5GT7 Hunter Green (GR) Body* Pastel Deep Green (PDG) 5822(Grizzly 4WD) Frame Yamaha Black 0033 (YB) 5135

Front Bumper Yamaha Black 0033 (YB) 5135Wheel Low Gloss Black 0098 (LGB) 5654

Beige (E) Body* Dark Grayish Yellow Solid 1 0598 (DNYS1) 5901Frame Yamaha Black 0033 (YB) 5135Front Bumper Yamaha Black 0033 (YB) 5135Wheel Low Gloss Black 0098 (LGB) 5654

Red (R) Body* Romantique Rouge 00TR (RTR) 5650Frame Yamaha Black 0033 (YB) 5135Front Bumper Yamaha Black 0033 (YB) 5135Wheel Low Gloss Black 0098 (LGB) 5654

YFM400AM / C 5HA1 / 5HA2 Hunter Green (GR) Body* Pastel Deep Green (PDG) 5822(Kodiak 2WD) Frame Yamaha Black 0033 (YB) 5135



Red (R) Body* Romantique Rouge (RTR) 5650Frame Yamaha Black 0033 (YB) 5135Front Bumper Yamaha Black 0033 (YB) 5135Wheel Low Gloss Black 0098 (LGB) 5654

YFM400FAHM / C 5GH6 / 5GH7 Hunter Green Body* Pastel Deep Green (PDG) 5822(Kodiak 4WD) (w/ Realtree X-tra® Seat) Frame Yamaha Black 0033 (YB) 5135 (w/ Camo Seat) Front Bumper Low Gloss Black 0098 (LGB) 5654

Wheel Mat Black 2 0582 (MBL2) 5988

YFM400FAM / C 5GH1 / 5GH2 Hunter Green (GR) Body* Pastel Deep Green (PDG) 5822(Kodiak 4WD) Frame Yamaha Black 0033 (YB) 5135



Red (R) Body* Romantique Rouge (RTR) 5650Frame Yamaha Black 0033 (YB) 5135Front Bumper Yamaha Black 0033 (YB) 5135Wheel Low Gloss Black 0098 (LGB) 5654

Sales Paint Yamaha Color-Rite Model Model Code Color Name* Component Color Name Paint Code Paint Code

ATV - 2000

Paint Reference Chart

PAGE 3 of 5



The letter in parenthesis is the Sales Color Code - Color Rite Paint Code Information:

NOTE: When ordering i.e. (R). 1000 series codes are base coats.pre-painted or plastic 5000 series codes are color coats.body parts from the All color coats must be clear coated.Parts Catalog, check Use low-gloss clear for low-gloss paints.the first page of the parts list, the code next to the part number, andthis chart for colorverification. Continued on next page

*Paint code forreference only - Do not paintplastic bodyparts.

Frame00K0

00K0

00K0

00K0

00K0

00TR

00TR


YFM400FHM 5FU5 Buckmaster Edition Body* N/A(Big Bear 4WD) (Realtree X-tra®) Frame Yamaha Black 0033 (YB) 5135

Front Bumper Yamaha Black 0033 (YB) 5135Wheel Yamaha Black 0033 (YB) 5135

YFM400FM / C 5FU1 / 5FU2 Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) 5822(Big bear 4WD) Frame Yamaha Black 0033 (YB) 5135

Front Bumper Titanic Gray Metallic 00MA (TGM) 5860Wheel Titanic Gray Metallic 00MA (TGM) 5860

Beige (E) Body* Dark Grayish Yellow Solid 1 0598 (DNYS1) 5901Frame Yamaha Black 0033 (YB) 5135Front Bumper Titanic Gray Metallic 00MA (TGM) 5860Wheel Titanic Gray Metallic 00MA (TGM) 5860

Red (R) Body* Romantique Rouge 00TR (RTR) 5650Frame Yamaha Black 0033 (YB) 5135Front Bumper Titanic Gray Metallic 00MA (TGM) 5860Wheel Titanic Gray Metallic 00MA (TGM) 5860

YFM400M / C 5GW1 / 5GW2 Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) 5822(Big Bear 2WD) Frame Yamaha Black 0033 (YB) 5135



Red (R) Body* Romantique Rouge 00TR (RTR) 5650Frame Yamaha Black 0033 (YB) 5135Front Bumper Titanic Gray Metallic 00MA (TGM) 5860 Wheel Titanic Gray Metallic 00MA (TGM) 5860

YFM350FXM / C 4KBG / 4KBH Team Yamaha Blue (L) Body* Deep Purplish Blue Solid E 0583 (DPBSE) 5829(Wolverine 4WD) Frame Yamaha Black 0033 (YB) 5135

Front Bumper Silver 0035 (SL) 5616Wheel Silver 0035 (SL) 5616

Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) 5822Frame Yamaha Black 0033 (YB) 5135Front Bumper Titanic Gray Metallic 00MA (TGM) 5860Wheel Titanic Gray Metallic 00MA (TGM) 5860

YFZ350M 5FK6 Team Yamaha Blue / White (L) Body* Deep Purplish Blue Solid E 0583 (DPBSE) 5829(Banshee) Frame Silver 0035 (SL) 5616

Front Bumper Silver 0035 (SL) 5616Wheel N/A

Red / White (W) (Red) Romantique Rouge 00TR (RTR) 5650(White) Body* Radical White 00UJ (RW) 5457

Frame Silver 0035 (SL) 5616Front Bumper Silver 0035 (SL) 5616Wheel N/A


ATV - 2000 (Cont’d)


PAGE 4 of 5




NOTE: When ordering i.e. (R). 1000 series codes are base coats.pre-painted or plastic 5000 series codes are color coats.body parts from the All color coats must be clear coated.Parts Catalog, check Use low-gloss clear for low-gloss paints.the first page of the parts list, the code next to the part number, andthis chart for colorverification. Continued on next page


N/A - Not Available

Body*



YFM350XM / C 3GDU / 3GDV Team Yamaha Blue / White (L) Body* Deep Purplish Blue Solid E 0583 (DPBSE) 5829(Warrior) Frame Silver 0035 (SL) 5616

Front Bumper Silver 0035 (SL) 5616Wheel N/A

Red / White (W) (Red) Romantique Rouge 00TR (RTR) 5650(White) Body* Radical White 00UJ (RW) 5457

Frame Silver 0035 (SL) 5616Front Bumper Silver 0035 (SL) 5616Wheel N/A

YFB250FM 4KDL Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) 5822(Timberwolf) Frame Yamaha Black 0033 (YB) 5135


YFM250XM / C 4XE5 / 4XE6 Hunter Green (GR) Body* Pastel Deep Green 00K0 (PDG) 5822(BearTracker) Frame Yamaha Black 0033 (YB) 5135



Red (R) Body* Romantique Rouge 00TR (RTR) 5650Frame Yamaha Black 0033 (YB) 5135Front Bumper Titanic Gray Metallic 00MA (TGM) 5860Wheel Titanic Gray Metallic 00MA (TGM) 5860

YFS200M 5KJ1 Team Yamaha Blue / White (L) Body* Deep Purplish Blue Solid E 0583 (DPBSE) 5829(Blaster) Frame Silver 0035 (SL) 5616


Red / White (W) (Red) Body* Romantique Rouge 00TR (RTR) 5650(White) Body* Radical White 00UJ (RW) 5457

Frame Silver 0035 (SL) 5616Front Bumper Silver 0035 (SL) 5616Wheel Silver 0035 (SL) 5616

YFA1M / C 3FAR / 3FAP Blue / White (L) (Blue) Deep Purplish Blue Solid E 0583 (DPBSE) 5829(Breeze) (White) Body* Radical White 00UJ (RW) 5457

Frame Yamaha Black 0033 (YB) 5135Front Bumper Yamaha Black 0033 (YB) 5135Wheel Silver 0035 (SL) 5616

YFM80M / C 4EMT / 4EMS Blue / White (L) (Blue) Body* Deep Purplish Blue Solid E 0583 (DPBSE) 5829(Badger) (White) Body* Radical White 00UJ (RW) 5457

Frame Yamaha Black 0033 (YB) 5135 Front Bumper Yamaha Black 0033 (YB) 5135 Wheel Silver 0035 (SL) 5616


ATV - 2000 (Cont’d)


PAGE 5 of 5




NOTE: When ordering i.e. (R). 1000 series codes are base coats.pre-painted or plastic 5000 series codes are color coats.body parts from the All color coats must be clear coated.Parts Catalog, check Use low-gloss clear for low-gloss paints.the first page of the parts list, the code next to the part number, andthis chart for colorverification.


N/A - Not Available

Body*

Body*


2000 MODELSATV SERVICE LITERATURE

© 1999 YAMAHAMOTORCORPORATION, U.S.A.

ATV 9/29/99 AT99-004

PAGE 1 of 3

The following is a comprehensive listing of service literature part numbers for 2000 Yamaha ATV’s.

If the service literature used in prior years is still current, the literature part number will still be listed,but “Same as . . .” will appear in the appropriate Manual column.


ì Badgerî 79 LIT-11626-13-03 LIT-11666-08-19 LIT-11616-08-19YFM80M LIT-11616-13-28

(Supplement)ì Badgerî (Calif.) 79 LIT-11626-13-28 LIT-11666-08-19 LIT-11616-08-19YFM80MC LIT-11616-13-28

(Supplement)î Breezeî 124 LIT-11626-13-04 LIT-11666-06-75 LIT-11616-YF-00YFA1M * LIT-11616-13-04

(Supplement)î Breezeî (Calif.) 124 LIT-11626-13-04 LIT-11666-06-75 LIT-11616-YF-00YFA1M * LIT-11616-13-04

(Supplement)ì Blasterî 195 LIT-11626-13-07 LIT-11666-07-20 LIT-11616-07-20YFS200M

ì Bear Trackerî 229.6 LIT-11626-13-14 LIT-11666-12-01 LIT-11616-12-01YFM250XM

ì Bear Trackerî (Calif.) 229.6 LIT-11626-13-14 LIT-11666-12-01 LIT-11616-12-01YFM250XMC

ì Timberwolfî 4WD 229.6 LIT-11626-13-02 LIT-11666-09-80 LIT-11616-09-11YFB250FWM

ì Wolverineî 348 LIT-11626-13-05 LIT-11666-09-58 LIT-11616-FX-36YFM350FXM * LIT-11616-12-03

* LIT-11616-13-05(Supplements)

*This supplement is included in the main book, but is also available separately.

PAGE 2 of 3


ì Wolverineî (Calif.) 348 LIT-11626-13-05 LIT-11666-09-58 LIT-11616-FX-36YFM350FXMC * LIT-11616-12-03


ì Warriorî 348 LIT-11626-13-08 LIT-11666-08-60 LIT-11616-YM-36YFM350XM LIT-11616-10-89

(Supplement)ì Warriorî (Calif.) 348 LIT-11626-13-08 LIT-11666-08-60 LIT-11616-YM-36YFM350XMC LIT-11616-10-89

(Supplement)ì Bansheeî 347 LIT-11626-13-09 LIT-11666-07-86 LIT-11616-YF-35YFZ350M LIT-11616-10-95

(Supplement)ì Kodiakî 2WD 386 LIT-11626-13-39 LIT-11666-13-39 LIT-11616-13-21YFM400AM LIT-11616-13-39

(Supplement)ì Kodiakî 2WD (Calif.) 386 LIT-11626-13-39 LIT-11666-13-39 LIT-11616-13-21YFM400AMC LIT-11616-13-39

(Supplement)ì Kodiakî 4WD 386 LIT-11626-13-21 LIT-11666-13-21 LIT-11616-13-21YFM400FAM

ì Kodiakî 4WD (Calif.) 386 LIT-11626-13-21 LIT-11666-13-21 LIT-11616-13-21YFM400FAMC

ì Kodiak - Real Treeî 4WD 386 LIT-11626-13-21 LIT-11666-13-21 LIT-11616-13-21YFM400FAHM

ì Kodiak - 386 LIT-11626-13-21 LIT-11666-13-21 LIT-11616-13-21Real Treeî 4WD(Calif.)YFM400FAHMC

ì Big Bearî 2WD 386 LIT-11626-13-34 LIT-11666-13-34 LIT-11616-13-22YFM400NM LIT-11616-13-34

(Supplement)ì Big Bearî 2WD (Calif.) 386 LIT-11626-13-34 LIT-11666-13-34 LIT-11616-13-22YFM400NMC LIT-11616-13-34

(Supplement)ì Big Bearî 4WD 386 LIT-11626-13-22 LIT-11666-13-22 LIT-11616-13-22YFM400FWNM

ì Big Bearî 4WD (Calif.) 386 LIT-11626-13-22 LIT-11666-13-22 LIT-11616-13-22YFM400FWNMC

ì Big Bear - 386 LIT-11626-13-22 LIT-11666-13-22 LIT-11616-13-22Buckmasterî 4WDYFM400FWNHM

ì Grizzlyî 595 LIT-11626-13-06 LIT-11666-11-02 LIT-11616-FW-00YFM600FWAM * LIT-11616-11-21


ì Grizzlyî (Calif.) 595 LIT-11626-13-06 LIT-11666-11-02 LIT-11616-FW-00YFM600FWAMC * LIT-11616-11-21




PAGE 3 of 3


ì Grizzly - Real Treeî 595 LIT-11626-13-06 LIT-11666-11-02 LIT-11616-FW-00YFM600FWHM * LIT-11616-11-21


ì Grizzly - 595 LIT-11626-13-06 LIT-11666-11-02 LIT-11616-FW-00Real Treeî (Calif.) * LIT-11616-11-21YFM600FWHMC * LIT-11616-12-37

(Supplements)



1999 MODELSATV PRIMARY I.D. NUMBERS & SERVICE LITERATURE


ATV 03/26/99 AT99-001A

PAGE 1 of 2

The following is a comprehensive listing of Primary I.D. numbers and service literature part numbersfor 1999 Yamaha ATV’s. The frame numbers of a unit is now the Primary I.D. for warranty purposes.Because the engine number may not match the frame number, be sure to use the frame number in allwarranty documents. Production started with the listed numbers below. For more details, see TechnicalBulletin AT97-006.

If the service literature used in prior years is still current, the literature part number will still be listed,but “Same as . . .” will appear in the appropriate Manual column.

Actual StartingDisplace- Frame Numbers Owner’s Assembly Service

Model ment (Primary I.D.) Manual Manual Manual“Badger” 79 4EM-095264 LIT-11626-12-50 LIT-11666-08-19 LIT-11616-08-19YFM80L Same as Same as

YFM80D~K YFM80D~K”Breeze” 124 3FA-107718 LIT-11626-12-44 LIT-11666-06-75 LIT-11616-06-75YFA1L Same as Same as

YFA W~K YFA W~K“Blaster” 195 3JM-289187 LIT-11626-12-51 LIT-11666-07-20 LIT-11616-07-20YFS200L Same as Same as

YFS200A~K YFS200U~K“Timberwolf” 229.6 4KD-118196 LIT-11626-12-45 LIT-11666-09-80 LIT-11616-09-11YFB250FWL Same as Same as

YFB250H~K YFB250H~K“Bear Tracker” 229.6 AG01W-000102 LIT-11626-12-46 LIT-11666-12-01 LIT-11616-12-01YFM250XL

”Bear Tracker” (Calif.) 229.6 AG01Y-000101 LIT-11626-12-46 LIT-11666-12-01 LIT11616-12-01YFM250XLC

“Big Bear”4WD 348 4WU-057914 LIT-11626-12-48 LIT-11666-10-58 LIT-11616-10-58YFM350FWBL Same as Same as

YFM350FWB J~K YFM350FWB J~KLIT-11616-10-93LIT-11616-12-10(Supplements)

Effective 3/26/99, this Technial Bulletin replaces AT99-001; please remove anddestroy AT99-001. Denotes a change in the original Technical Bulletin.

PAGE 2 of 2

Actual StartingDisplace- Frame Numbers Owner’s Assembly Service

Model ment (Primary I.D.) Manual Manual Manual“Big Bear”4WD (Calif.) 348 AH02Y-000328 LIT-11626-12-48 LIT-11666-10-58 LIT-11616-10-58YFM350FWBLC Same as Same as

YFM350FWB J~K YFM350FWB J~K LIT-11616-10-93LIT-11616-12-10(Supplements)

“Big Bear”2WD 348 AH03W-000007 LIT-11626-12-49 LIT-11666-10-08 LIT-11616-10-08YFM350UBL Same as Same as

YFM350UB H~K YFM350UB H~KLIT-11616-12-02

(Supplement)“Big Bear”2WD (Calif.) 348 AH03Y-000001 LIT-11626-12-49 LIT-11666-10-08 LIT-11616-10-08YFM350UBLC Same as Same as

YFM350UB H~K YFM350UB H~KLIT-11616-12-02

(Supplement)“Wolverine” 348 4KB-078283 LIT-11626-12-47 LIT-11666-09-58 LIT-11616-FX-35YFM35FXL Same as

YFM350FX G~K”Wolverine”(Calif.) 348 AH04Y-000003 LIT-11626-12-47 LIT11666-09-58 LIT-11616-FX-35YFM35FXLC Same as

YFM350FX G~K“Warrior” 348 3GD-225942 LIT-11626-12-53 LIT-11666-08-60 LIT-11616-YM-36YFM350XL Same as Same as

YFM350X E~K YFM350X A~KLIT-11616-10-89LIT-11616-10-28

(Supplements)“Warrior”(Calif.) 348 4KD-118196 LIT11626-12-53 LIT-11666-08-60 LIT-11616-YM-36YFM350XLC Same as Same as

YFM350X E~K YFM350X A~KLIT-11616-10-89LIT-11616-10-28

(Supplements)”Banshee” 347 3GG-150917 LIT-11626-12-52 LIT11666-07-86 LIT-11616-YF-35YFZ350L Same as Same as

YFM350X B~K YFM350X T~KLIT-11616-10-95

(Supplement)“Kodiak”4WD 386 AH05W-000018 LIT11626-12-24 LIT-11666-12-24 LIT-11616-KD-40YFM400FWBL Same as

YFM400FWB E~KLIT-11616-12-24

(Supplement)“Kodiak” 4WD (Calif.) 386 AH05Y-000001 LIT-11626-12-24 LIT-11666-12-24 LIT-11616-KD-40

Same asYFM400FWBLC YFM400FWB E~K

LIT-11616-12-24(Supplement)

“Grizzly” 595 AJ02W-000020 LIT-11626-12-37 LIT-11666-11-02 LIT-11616-11-02 YFM600FWAL Same as

YFM600FWAKLIT-11616-12-37LIT-11616-11-21(Supplements)

“Grizzly” (Calif.) 595 AJ02Y-000001 LIT-11626-12-37 LIT-11666-11-02 LIT-11616-11-02YFM600FWALC Same as

YFM600FWAKCLIT-11616-12-37LIT-11616-11-21(Supplements)

1999 ATV Primary ID Numbers & Service Literature



ATVService Data

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 39 x 41.4mm (1.54 x 1.63 in) Number Cylinders / Displacement. . . . . . . . . . . . . . 1 / 49cc (2.99 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.05 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . 0.075 ~ 0.125mm (0.003 ~ 0.005 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . N/A - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 0.8L (0.9 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Mikuni / VM16SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.5 / 15 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . D-8M / 3PZ13 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 2 / 3.0 Float Height . . . . . . . . . . . . . . . . . . . . . . 20 ~ 22mm (0.79 ~ 0.87 in) Fuel Level . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0mm (0.16 ~ 0.20 in) Below Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 ~ 1850 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 6.0% Fuel Tank Capacity - Main / Reserve . . . . 6.8L (1.8 US gal) / 0.9L (0.24 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . Constant Mesh, Semi-Automatic Clutch, 3 Speed Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.12L (0.13 US qt)

SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.00 ~ 0.39 in)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT16 x 7-7 - Nominal Pressure . . . . . . . . . . . . . . . . . 17 ~ 23kPa (2.5 ~ 3.3 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT16 x 8-7 - Nominal Pressure . . . . . . . . . . . . . . . . . 17 ~ 23kPa (2.5 ~ 3.3 psi)

June 2009

YFM50Service Data

2004~2008“Raptor 50”

(5YF)

YFM50 2004~2008 “Raptor 50” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR7HS Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.024 ~ 0.028 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/L / 264 ~ 396Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . G/W ~ B/R / 304 ~ 456Ω

CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12N7D-3B System Maximum Output . . . . . . . . . . . . . . . . . 14V 3.2A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . B ~ W / 0.72 ~ 1.08Ω

LIGHTING SYSTEM:

System Maximum Output . . . . . . . . . . . . . . . . . . . 15.5V @ 8000 RPM Lighting Coil Color Code / Ω . . . . . . . . . . . . . . . B ~ Y/R / 0.32 ~ 0.48Ω Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14 ft-lb) Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb) Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50 ft-lb)

TUNE UP / MAINTENANCE PARTS:

Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR7HS-A0-00 Oil Filter Type / Part Number . . . . . . . . . . . . . . Screen / 22F-13411-01-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 55X-14451-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4KN-W2536-11-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3KG-W2536-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 5G2-82151-00-00 (5A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 812-11198-00-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 22F-14150-00-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 22F-14184-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-12N7D-3B-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26311-02-00 Front Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26361-03-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26341-01-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 3GB-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 1NV-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 47 x 45.6mm (1.85 x 1.80 in) Number Cylinders / Displacement. . . . . . . . . . . . . . 1 / 79cc (4.83 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.05 ~ 0.10mm (0.002~0.004 in) - Exhaust . . . . . . . . . . . . . . . . 0.075 ~ 0.125mm (0.003 ~ 0.005 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°*C (60°F). . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil Change. . . . . . . . . . . . . . . . . . . . . . . 0.8L (0.9 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Mikuni / VM16SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.3 / 12.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 Needle Jet / Jet Needle . . . . . . . . . . . . . D-8M / 3PZ13 (CA. D-8M / 3PZ8) Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . 2 / 3.5 (CA 1 /3.5) Float Height . . . . . . . . . . . . . . . . . . . . . . 20 ~ 22mm (0.79 ~ 0.87 in) Fuel Level . . . . . . . . . . . . . . . . . . . 2.5 ~ 4.5mm (0.10 ~ 0.18 in) Below Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 ~ 1850 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . . 6.8L (1.8 US gal) / 0.9L (0.24 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . Constant Mesh, Semi-Automatic Clutch, 3 Speed Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.12L (0.13 US qt)

SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.00 ~ 0.39 in)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT18 x 7-7 - Nominal Pressure . . . . . . . . . . . . . 0.17 ~ 0.23 Kg/cm (2.5 ~ 3.3 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT18 x 7-8 - Nominal Pressure . . . . . . . . . . . . . 0.17 ~ 0.23 Kg/cm (2.5 ~ 3.3 psi)

April 2005

YFM80Service Data

1995~2001“Badger”

(4EM)

YFM80 1995~2001 “Badger” Service Data

IGNITIoN SYSTEM:


CHARGING SYSTEM:


LIGHTING SYSTEM:

System Maximum Output . . . . . . . . . . . . . . . . . . . 15.5V @ 8000 RPM Lighting Coil Color Code / Ω . . . . . . . . . . . . . . . B ~ Y/R / 0.32 ~ 0.48Ω Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR7HS-A0-00 Oil Filter Type / Part Number . . . . . . . . . . . . . . Screen / 22F-13411-01-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 55X-14451-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4KN-W2536-11-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3KG-W2536-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 5G2-82151-00-00 (5A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 812-11198-00-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 22F-14150-00-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 22F-14184-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-12N7D-3B-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26311-02-00 Front Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26361-03-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26341-01-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 3GB-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 1NV-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 47 x 45.6mm (1.85 x 1.80 in) Number Cylinders / Displacement. . . . . . . . . . . . . . 1 / 79cc (4.83 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.05 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . 0.075 ~ 0.125mm (0.003 ~ 0.005 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 35°C (95°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil Change. . . . . . . . . . . . . . . . . . . . . . . 0.8L (0.9 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Mikuni / VM16SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.3 / 12.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 Needle Jet / Jet Needle . . . . . . . . . . . . . D-8M / 3PZ13 (CA D-8M / 3PZ8) Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . 2 / 3.5 (CA 1 / 3.5) Float Height . . . . . . . . . . . . . . . . . . . . . 20 ~ 22mm (0.79 ~ 0.87 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . 2.5 ~ 4.5mm (0.10 ~ 0.18 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 - 1850 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . . 6.8L (1.8 US gal) / 0.9L (0.24 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Speed Semi Automatic Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø

FINAL DRIVE:


SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in)

TIRES:


June 2009

YFM80GService Data

2005~2008“Grizzly 80”

(2D3)

YFM80G 2005~2008 “Grizzly 80” Service Data

IGNITIoN SYSTEM:


CHARGING SYSTEM:


LIGHTING SYSTEM:


ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR7HS-A0-00 Oil Filter Type / Part Number . . . . . . . . . . . . . . Screen / 22F-13411-01-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 55X-14451-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4KN-W2536-11-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3KG-W2536-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 5G2-82151-00-00 (5A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 812-11198-00-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 22F-14150-00-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 22F-14184-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-12N7D-3B-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26311-02-00 Front Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26361-03-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26341-01-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 3GB-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 23X-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 47 x 45.6mm (1.85 x 1.80 in) Number Cylinders / Displacement. . . . . . . . . . . . . . 1 / 79cc (4.83 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.05 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . 0.075 ~ 0.125mm (0.003 ~ 0.005 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 35°C (95°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil Change. . . . . . . . . . . . . . . . . . . . . . . 0.8L (0.9 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Mikuni / VM16SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.3 / 12.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 Needle Jet / Jet Needle . . . . . . . . . . . . . D-8M / 3PZ13 (CA D-8M / 3PZ8) Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . 2 / 3.5 (CA 1 / 3.5) Float Height . . . . . . . . . . . . . . . . . . . . . . 20 ~ 22mm (0.79 ~ 0.87 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . 2.5 ~ 4.5mm (0.10 ~ 0.18 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 - 1850 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . . 6.8L (1.8 US gal) / 0.9L (0.24 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in)

TIRES:


June 2009

YFM80WService Data

2002~2008“Raptor 80”

(5TH)

YFM80W 2002~2008 “Raptor 80” Service Data

IGNITIoN SYSTEM:


CHARGING SYSTEM:


LIGHTING SYSTEM:


ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR7HS-A0-00 Oil Filter Type / Part Number . . . . . . . . . . . . . . Screen / 22F-13411-01-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 55X-14451-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4KN-W2536-11-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3KG-W2536-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 5G2-82151-00-00 (5A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 812-11198-00-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 22F-14150-00-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 22F-14184-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-12N7D-3B-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26311-02-00 Front Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26361-03-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26341-01-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 3GB-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 1NV-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . Air Cooled, 4-Stroke, Single Cylinder, SOHCBore x Stroke . . . . . . . . . . . . . . . . . . . . 47.0 x 51.0mm (1.85 x 2.01 in)Number Cylinders / Displacement . . . . . . . . . . . . 1 / 88.0cc (5.36 cu. in)Valve Clearance (Cold) - Intake . . . . . . . . . . . . . . . . . 0.07mm (0.003 in) - Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07mm (0.003 in)Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . Yamalube 4, 20W50Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40Oil Type - Below 0°C (32°F). . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30Capacity - Oil & Filter Change . . . . . . . . . . . . . . . . 0.80 L (0.85 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . 0.75 L (0.80 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single CarburetorManufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . TK / SVR 22-1GMain Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 / 32Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/ANeedle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . 2.090 H5.5 / 4T12 1Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / 2.3Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5mm (1.00 in)Fuel Level . . . . . . . . . . . . . . . . . . . . . . 5.0 ~ 6.0mm (0.20 ~ 0.24 in)Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600 ~ 1800 rpmSet CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 ~ 4.0%Fuel Tank Capacity - Main / Reserve . . 4.8 L (1.27 US gal) / 1.0 L (0.26 US gal)Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully AutomaticOil Type / Capacity . . . SAE 80 API “GL-4” Hypoid Gear Oil / 0.3 L (0.32 US qt)V-Belt Width / Limit . . . . . . . . . . . . 18.0mm (0.708 in) / 17.0mm (0.669 in)

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain Drive

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . . . . 15.0mm (0.59 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT18 x 7-8 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.25 Kg/cm (3.6 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT18 x 9-8 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.25 Kg/cm (3.6 psi)

June 2009

YFM90RService Data

2009~“Raptor 90”

(43D)

YFM90R 2009~ “Raptor 90” Service Data

IGNITIoN SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDISpark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR7HSASpark Plug Gap . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.024 ~ 0.028 in)Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0KΩIgnition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)Primary Ω / Secondary Ω . . . . . . . . . . . . 0.189 ~ 0.231Ω / 2.79 ~ 3.41KΩPickup Coil Color Code / Ω . . . . . . . . . . . . . . . . W/L ~ W/R / 94 ~ 140ΩSource Coil Color Code / Ω . . . . . . . . . . . . . . . . B/G ~ B/R / 640 ~ 960ΩCHARGING SYSTEM:Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . AC MagnetoBattery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . GTX5L - BSSystem Maximum Output . . . . . . . . . . . . . . . 14.0V, 85 W @ 5000 RPMStator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.60 ~ .90ΩLIGHTING SYSTEM:System Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . N/ALighting Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . . . . . N/AIndicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AToRqUE VALUES:Engine Drain Plug. . . . . . . . . . . . . . . . . . . . . M30: 0.8m-kg (5.8 ft-lb)Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.1m-kg (8.0 ft-lb)Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (33 ft-lb)Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M14: 6.5m-kg (47 ft-lb)Rear Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb)Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (33 ft-lb)Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M14: 13.5m-kg (98 ft-lb)Rear Axle Nuts . . . . . . . . . . . . . . . . M28: Inside Nut: 6.0m-kg (43 ft-lb) Outside Nut: 17.0m-kg (123 ft-lb)Rear Axle Pinch Bolts . . . . . . . . . . . . . . . . . . . M12: 5.5m-kg (40 ft-lb)Drive Sprocket Nuts . . . . . . . . . . . . . . . . . . . . . M6: 1.0m-kg (7.2 ft-lb)Driven Sprocket Nuts . . . . . . . . . . . . . . . . . . . M10: 3.5m-kg (25 ft-lb)TUNE UP / MAINTENANCE PARTS:Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR7HS-A0-00Oil Filter Type / Part Number . . . . . . . . . . . . . Strainer / 43D-E3411-00-00Air Filter Type / Part Number . . . . . . . . . . Foam / 43D-E4451-00-00 (qty 2)Air Filter Guide . . . . . . . 43D-E4468-00-00 (qty 2), 43D-E440H-00-00 (qty 2)Front Brake Lining. . . . . . . . . . . . . . . . . . . . . . . . 43D-F510L-00-00Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 43D-F5906-00-00Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 43D-H2151-00-00 (10A)Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . 43D-E319C-00-00Float Valve Needle . . . . . . . . . . . . . . . . . . . . . . . 43D-E4392-00-00Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5WB-E4384-00-00V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43D-E7641-00-004 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yamlube 20W504 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . Yamalube 10W404 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . Yamalube 05W30 / 05W40Transmission Oil. . . . . . . . . Yamalube Friction Modified Shaft Drive Gear OilBattery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTG-GTX5L-BS-00Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 43D-F6311-00-00Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 43D-F6331-00-00Front Brake Cable . . . . . . . . . . . . . . 43D-F6340-00-00, 43D-F6350-00-00Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 43D-H3922-00-00Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 43D-H3912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 49 x 66mm (1.93 x 2.60 in) Number Cylinders / Displacement. . . . . . . . . . . . . . 1 / 124cc (7.59 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.08 ~ 0.12mm (0.003 ~ 0.005 in) - Exhaust . . . . . . . . . . . . . . . . . 0.10 ~ 0.14mm (0.004 ~ 0.006 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 35°C (95°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil Change. . . . . . . . . . . . . . . . . . . . . . . 1.3L (1.3 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Mikuni / VM18SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . 82.5 / 12.5 (CA. 77.5 / 12.5) Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . N-6 / 4H36 (CA. 0-1M / 4HPY46) Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . 3 / 2.5 (CA. 1 / 2.5) Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8mm (0.86 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . 4 ~ 6mm (0.16 ~ 0.24 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1650 - 1750 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . . 7.0L (1.8 US gal) / 1.3L (0.34 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt Automatic Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 35°C (95°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil Change. . . . . . . . . . . . . . . . . . . . . . 0.6L (0.63 US qt) V-Belt Width / Limit . . . . . . . . . . . . 20.1mm (0.791 in)/ 18.1mm (0.712 in)

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain - Chain Free Play . . . . . . . . . . . . . . . . . . . . . . . . 30mm (1.18 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 74 - Drive Sprocket Teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - Driven Sprocket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT20 x 7-8 - Nominal Pressure . . . . . . . . . . . . . . . . . 17 ~ 23kPa (2.5 ~ 3.3psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 10-8 - Nominal Pressure . . . . . . . . . . . . . . . . . 22 ~ 28kPa (3.2 ~ 4.1psi)

April 2005

YFA1Service Data

1995~2004“Breeze”

(3FA)

YFA1 1995~2004 “Breeze” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR7HS Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.024 ~ 0.028 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.56 ~ 0.84Ω / 5.70 ~ 8.50KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . W ~ R / 248 ~ 372Ω

CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 12N12C-4A-2 System Maximum Output . . . . . . . . . . . . . . . . . 14V 3.5A @ 8000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . . B ~ Y 0.72 ~ 1.08Ω

LIGHTING SYSTEM:

System Maximum Output . . . . . . . . . . . . . . . . . . . 14.8V @ 8000 RPM Lighting Coil Color Code / Ω . . . . . . . . . . . . . . . . Y ~ B / 0.32 ~ 0.48Ω Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 25W-25W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . 12V 21W-12V5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M34: 3.2m-kg (23 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M16: 7.0m-kg (50 ft-lb) Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 12.0m-kg (87 ft-lb) Rear Axle Nut (See Service Manual for Procedure). . . M38 24.0m-kg (170 ft-lb)


Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR7HS-A0-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . Screen / 51Y-13411-00-00 Air Filter Type & Part Number . . . . . . . . . . . . Washable / 2XJ-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 2XJ-14458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 4BE-W253E-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 3FA-W253A-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 102-84314-00-XX Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 5G2-82151-00-00 (5A) Drain Bolt 0 Ring . . . . . . . . . . . . . . . . . . . . . . . . . 93210-347A1-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 21V-14190-18-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 24W-14184-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (5W30) Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB12C-A0-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 3FA-26311-01-00 Choke Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3FA-26331-01-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3FA-26351-02-00 Front Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3GB-26361-03-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 59V-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

June 2009

YFM125GService Data

2005~“Grizzly 125”

(1C5)

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 49 x 66mm (1.93 x 2.60 in) Number Cylinders / Displacement. . . . . . . . . . . . . . 1 / 124cc (7.59 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.08 ~ 0.12mm (0.003 ~ 0.005 in) - Exhaust . . . . . . . . . . . . . . . . . 0.10 ~ 0.14mm (0.004 ~ 0.006 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 35°C (95°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil Change. . . . . . . . . . . . . . . . . . . . . . . 1.3L (1.3 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Mikuni / VM18SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.5 / 12.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . 0-1M / 4HPY46 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / 2.5 Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8mm (0.86 in) Fuel Level . . . . . . . . . . . . . 4 ~ 6mm (0.16 ~ 0.24 in) Below Gask. Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1650 ~ 1750 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . 7.6L (2.01 US gal) / 1.3L (0.34 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt Automatic with Reverse Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 35°C (95°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil Change. . . . . . . . . . . . . . . . . . . . . . 0.6L (0.63 US qt) V-Belt Width / Limit . . . . . . . . . . . . 20.1mm (0.791 in) / 18.1mm (0.712 in)

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain - Chain Free Play . . . . . . . . . . . . . . . . . . . . . . . . 30mm (1.18 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 74 - Drive Sprocket Teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - Driven Sprocket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT20 x 7-8 - Nominal Pressure . . . . . . . . . . . . . . . . . 17 ~ 23kPa (2.5 ~ 3.3 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 10-8 - Nominal Pressure . . . . . . . . . . . . . . . . 22 ~ 28kPa (3.2 ~ 4.1 psi)

YFM125G 2005~ “Grizzly 125” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR7HS Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.024 ~ 0.028 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 5.70 ~ 8.50KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . Gy ~ R / 280 ~ 420Ω

CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 12N12C-4A-2 System Maximum Output . . . . . . . . . . . . . . . . . . 14V 11A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . . B ~ W 0.56 ~ 0.84Ω

LIGHTING SYSTEM:

System Maximum Output . . . . . . . . . . . . . . . . . . . 14.8V @ 8000 RPM Lighting Coil Color Code / Ω . . . . . . . . . . . . . . . . Y ~ B / 0.32 ~ 0.48Ω Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . 12V 21W-12V 5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M34: 3.2m-kg (23 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb) Front Wheel Nut / Rear . . . . . M10: 5.5m-kg (40 ft-lb) / M10: 5.5m-kg (40 ft-lb) Front Hub Nut / Rear . . . . . . M16: 7.0m-kg (50 ft-lb) / M16: 12.0m-kg (87 ft-lb) Rear Axle Nut (See Service Manual for Procedure). . . M33 24.0m-kg (170 ft-lb) Chain Adjuster Lock Nuts . . . . . . . . . . . . . . . . . . M8: 1.6m-kg (11.0 ft-lb) Drive Sprocket Nuts . . . . . . . . . . . . . . . . . . . . . M12: 7.5m-kg (54 ft-lb) Driven Sprocket Nuts . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)


Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR7HS-A0-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . Screen / 51Y-13411-00-00 Air Filter Type & Part Number . . . . . . . . . . . . . . Foam / 2XJ-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 2XJ-14458-00-00 Front Brake Lining / Rear . . . . . . . . . 4BE-W253E-00-00 / 3FA-W253A-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-82151-00-00 (15A) Drain Bolt 0 Ring . . . . . . . . . . . . . . . . . . . . . . . . . 93210-347A1-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 21V-14190-18-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 24W-14184-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (5W30) Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTG-CB12C-A0-00 Throttle Cable / Choke Cable . . . . . . . . . 3FA-26311-01-00 / 3FA-26331-01-00 Front Brake Cable / Rear . . . . . . . . . . 3FAl-26373-00-00 / 3FA-26351-03-00 Front Brake Lever / Rear . . . . . . . . . . 59V-83922-00-00 / 2HT-83912-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 2 Stroke Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 66 x 57mm (2.60 x 2.24 in) Number Cylinders / Displacement. . . . . . . . . . . . . . 1 / 195cc (11.90 cu. in) Oil Type (Autolube Injection) / Ratio . . . . . . . . . . . . . . . . Yamalube 2S / ø

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Mikuni / VM26SS Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 / 32.5 Air Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . P-6 / 5J22 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 2 / 2.0 Float Height . . . . . . . . . . . . . . . . . . . . 20.5 ~ 21.5mm (0.81 ~ 0.85 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . 0.5 ~ 1.5mm (0.02 ~ 0.06 in) Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Fuel Tank Capacity - Main / Reserve . . . . . 9L (2.38 US gal) / 2L (0.53 US gal) Fuel Type / Octane . . . . . . . . . Premium Unleaded / ([R+M]/2) 90 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Speed Manual Oil Type / Capacity . . . . . . . . . . . . Yamalube 4, 10W30 / 0.7L (0.74 US qt)

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain - Chain Free Play . . . . . . . . . . . . . . . . . 30 ~ 40mm (1.18 ~ 1.57 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 92 - Drive Sprocket Teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - Driven Sprocket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . 2nd Position (From The Softest Setting) Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . 230mm (9.1 in)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT21 x 7-10 - Nominal Pressure . . . . . . . . . . . . . . . . 27 ~ 33kPa (3.9 ~ 4.8 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT21 x 10-8 - Nominal Pressure . . . . . . . . . . . . . . . . 22 ~ 28kPa (3.2 ~ 4.1 psi)

June 2009

YFS200Service Data

1995~2006“Blaster”

(5VM)

YFS200 1995~2006 “Blaster” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, B8ES Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.7 ~ 0.8mm (0.028 ~ 0.032 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.28 ~ 0.38Ω / 4.70 ~ 7.10KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . W/R ~ B / 16 ~ 24Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . B/R ~ B / 192 ~ 288Ω

LIGHTING SYSTEM:

System Maximum Output . . . . . . . . . . . . . . . . . . . 15.0V @ 8000 rpm Lighting Coil / Ω . . . . . . . . . . . . . . . . . . . . . . B/R ~ B / 0.16 ~ 0.24Ω Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 45W-45W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . 12V 21W-12V 5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M14: 2.5m-kg (18 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M14: 7.0m-kg (51 ft-lb) Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 12.0m-kg (87 ft-lb) Rear Axle Nut (See Service Manual for Procedure). . . M38: 24.0m-kg (170 ft-lb)


Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-B8ES0-00-00 Air Filter Type & Part Number . . . . . . . . . . . . Washable / 2XJ-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 2XJ-14458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 4BE-W253E-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 2XJ-25811-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 21V-84314-00-XX Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 90201-12172-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 2MA-14107-28-00 Float Bowl Gasket . . . . . . . . . . . . . . . . . . . . . . . . 304-14184-00-00 2 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . ACC-Y2R00-00-12 Transmission Oil . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 2XJ-26311-01-00 Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 2XJ-26335-01-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . 2XJ-26361-01-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 3GH-83922-10-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 23X-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . Air Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 71 x 58mm (2.80 x 2.28 in) Number Cylinders / Displacement. . . . . . . . . . . . 1 / 229.6cc (14.01 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.05 ~ 0.09mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.11 ~ 0.15mm (0.004 ~ 0.006 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 1.6L (1.7 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 1.5L (1.6 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Mikuni / VM24SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 / 20 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . O-0 / 5L10 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 4 / 3.5 Float Height . . . . . . . . . . . . . . . . . . . . . . 21 ~ 22mm (0.83 ~ 0.87 in) Fuel Level Measured From Gask Surface . . . . . 2 ~ 4mm (0.08 ~ 0.16 in) Below Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350 ~ 1450 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ~ 4.5% Fuel Tank Capacity - Main / Reserve . . . 9.2L (2.40 US gal) / 1.6L (0.42 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . Constant Mesh, Semi-Automatic Clutch, 5 Speed with 1 Reverse Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø

FINAL DRIVE:


SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 5mm (0.00 ~ 0.2 in)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 7.00-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.20 Kg/cm (2.8 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 10.00-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.20 Kg/cm (2.8 psi)

April 2005

YFB250Service Data

1995~1998“Timberwolf 2WD”

(4BD)

YFB250 1995~1998 “Timberwolf 2WD” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, D7EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.36 ~ 0.48Ω / 5.40 ~ 7.40KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 189 ~ 231Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . . BR-B / 270 ~ 330Ω

CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . GM12CZ-4A-2 System Maximum Output . . . . . . . . . . . . . . . . . 14V 4.5A @ 8000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ B / 0.72 ~ 0.88Ω

LIGHTING SYSTEM:

System Maximum Output . . . . . . . . . . . . . . . . . . . 13.8V @ 8000 rpm Lighting Coil Color Code / Ω . . . . . . . . . . . . . . . . Y ~ B / 0.48 ~ 0.58Ω Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 25W-25W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M35: 4.3m-kg (31 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR7EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 5H0-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1YW-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1YW-14458-01-00 Front / Rear Brake Lining . . . . . . . . . . . . . . . . . . . . 4BD-W2536-01-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 1YT-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-84714-00-XX Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 123-83516-21-XX Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705-82151-00-00 Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-347A1-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 21V-14190-18-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 24W-14184-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB12C-A0-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KD-26311-01-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 4BD-26331-00-00 Front Brake Cable / Rear Brake Cable . . . 4BD-26373-01-00 / 4KD-26341-01-00 Front Brake Lever / Front Brake Lever . . . 59V-83922-00-00 / 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . Air Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 71 x 58mm (2.80 x 2.28 in) Number Cylinders / Displacement. . . . . . . . . . . . 1 / 229.6cc (14.01 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.05 ~ 0.09mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.11 ~ 0.15mm (0.004 ~ 0.006 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 1.6L (1.7 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 1.5L (1.6 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Mikuni / VM24SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 / 20 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . O-4 / 5L10 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 4 / 3.5 Float Height . . . . . . . . . . . . . . . . . . . . . . 21 ~ 22mm (0.83 ~ 0.87 in) Fuel Level Measured From Gask Surface . . . . . 2 ~ 4mm (0.08 ~ 0.16 in) Below Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350 ~ 1450 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ~ 4.5% Fuel Tank Capacity - Main / Reserve . . . 9.2L (2.40 US.gal) / 1.6L (0.42 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . Constant Mesh, Semi-Automatic Clutch, 5 Speed with 1 Reverse Oil Type / Capacity . . . SAE 80 API “GL-4” Hypoid Gear Oil / 0.67L (0.71 US qt)

FINAL DRIVE:


SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.00 ~ 0.39 in)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 7.00-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.20 Kg/cm (2.9 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 10.00-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.25 Kg/cm (3.6 psi)

April 2005

YFB250FService Data

1995~2000“Timberwolf 4WD”

(4KD)

YFB250F 1995~2000 “Timberwolf 4WD” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, D7EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.36 ~ 0.48Ω / 5.40 ~ 7.40KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 189 ~ 231Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . BR ~ B / 428 ~ 532Ω

CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB12C-A System Maximum Output . . . . . . . . . . . . . . . . . 14V 4.5A @ 8000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ B / 0.72 ~ 0.88Ω

LIGHTING SYSTEM:

System Maximum Output . . . . . . . . . . . . . . . . . . . 13.8V @ 8000 rpm Lighting Coil Color Code / Ω . . . . . . . . . . . . . . . . Y ~ B / 0.48 ~ 0.58Ω Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 25W-25W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M35: 4.3m-kg (31 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR7EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 5H0-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1YW-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1YW-14458-01-00 Front / Rear Brake Lining . . . . . . . . . . . . . . . . . . . . 4BD-W2536-01-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 1YT-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-84714-00-XX Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 123-83516-21-XX Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705-82151-00-00 Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-347A1-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 21V-14190-18-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . . 24W-14184-00-0 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB12C-A0-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KD-26311-01-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 4BD-26331-00-00 Front Brake Cable / Rear Brake Cable . . . 4BD-26373-01-00 / 4KD-26341-01-00 Front Brake Lever / Rear Brake Lever. . . . 59V-83922-00-00 / 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled 4 Cycle, SOHCBore x Stroke . . . . . . . . . . . . . . . . . . . . . 71 x 58mm (2.80 x 2.28 in)Number Cylinders / Displacement . . . . . . . . . . . .1 / 229.6cc (14.01 cu. in)Valve Clearance (Cold) - Intake . . . . . . . . 0.05 ~ 0.09mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.11 ~ 0.15mm (0.004 ~ 0.006 in)Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . Yamalube 4, 20W50Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40Oil Type - Below 0°C (32°F). . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30Capacity - Oil & Filter Change . . . . . . . . . . . . . . . . . . 1.6L (1.7 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 1.5L (1.6 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single CarburetorManufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33Main Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.8 / 17.5Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-2M / 5EP20Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 2 / N/AFloat Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in)Fuel Level . . . . . . . . . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) AboveIdle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 ~ 1500 rpmSet CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0%Fuel Tank Capacity - Main / Reserve . . . . 12L (3.17 US gal) / 1.6L (0.42 US gal)Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . Constant Mesh, Semi-Automatic Clutch, 5 Speed with 1 ReverseOil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE

FINAL DRIVE:


SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 5mm (0.0 ~ 0.2 in)Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 7.00-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.20 Kg/cm (2.9 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 10.00-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.25 Kg/cm (3.6 psi)

June 2009

YFM25BService Data

2005~“Bruin 250/Big Bear 250”

(1P0)

YFM25B 2005~ “Bruin 250/Big Bear 250” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDISpark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR7EASpark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in)Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩIgnition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩPickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 168 ~ 252ΩRotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.058 ~ 0.086Ω

CHARGING SYSTEM:

Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . AC MagnetoBattery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB14A-A2System Maximum Output . . . . . . . . . . . . . . . . . . 14V 16A @ 5000 rpmStator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.43 ~ 0.65Ω

LIGHTING SYSTEM:

Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 25W-25WTaillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5WIndicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUEToR VALUES:

Engine Drain Plug. . . . . . . . . . . . . . . . . . . . . M35: 4.3m-kg (31 ft-lb)Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb)Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb)Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR7EA-00-00Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 5H0-13440-00-00Air Filter Type / Part Number . . . . . . . . . . . . . . Paper / 4XE-E4450-00-00Front Brake Lining. . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4XE-WF531-00-00Headlight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . 1YT-84314-00-00Taillight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 2GV-82151-00-00 (20A)Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-347A1-00Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . . 20W50 YamalubeOil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 YamalubeOil Type - Below 0°C (22°F). . . . . . . . . . . . . . . 5W40 or 5W30 YamalubeRear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB14A-A2-00Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-26311-11-00Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 4XE-26341-00-00Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83922-00-00Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 71 x 58mm (2.80 x 2.28 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 230cc (14.01 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.05 ~ 0.09mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.11 ~ 0.15mm (0.004 ~ 0.006 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 1.6L (1.7 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 1.5L (1.6 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BST34 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 / 42.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-2N / 5CE35 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 2 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . 1 ~ 2mm (0.04 ~ 0.08 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 - 1500 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 12.0L (3.2 US gal) / 1.6L (0.42 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 5mm (0.0 ~ 0.20 in) Rear - Spring Preload (Std) . . . . . . . . 2nd Position (From The Softest Setting)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 7-12 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . . . 20kPa (2.9 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 10-12 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . . . 25kPa (3.6 psi)

April 2005

YFM25XService Data

1999~2004“BearTracker”

(4XE)

YFM25X 1999~2004 “BearTracker” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR7EA Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.024 ~ 0.028 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 189 ~ 231Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.270 ~ 0.330Ω

CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB14A-A2 System Maximum Output . . . . . . . . . . . . . . . . . . 14V 16A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.43 ~ 0.65Ω

LIGHTING SYSTEM:

Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 25W-25W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . 12V 21W-12V 5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M35: 4.3m-kg (31 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)


Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR7EA-00-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . Cartridge / 5H0-13440-00-00 Oil Filter O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 93210-54175-00 Air Filter Type & Part Number . . . . . . . . . . . Disposable / 4XE-E4450-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4XE-WF531-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 1YT-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 2GV-82151-00-00 (20A) Drain Bolt O Ring . . . . . . . . . . . . . . . . . . . . . . . . . 93210-347A1-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (5W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB14A-A2-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-26311-11-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 4XE-26341-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . Air Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 83 x 64.5mm (3.27 x 2.54 in) Number Cylinders / Displacement. . . . . . . . . . . . 1 / 348.9cc (21.29 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.2L (2.3 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . 128.8 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . P-2M / 5ETY1-54 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 2 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (.51 in) Fuel Level . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gask. Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 13.5 L (3.6 US gal) / 3.L (0.87 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic With Reverse Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE

FINAL DRIVE:


SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)

June 2009

YFM35BAService Data

2004~2006“Bruin 2WD”

(5WH)

YFM35BA 2004~2006 “Bruin 2WD” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω

CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX14AH System Maximum Output . . . . . . . . . . . . . . . . . . 14V 16A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω

LIGHTING SYSTEM:

Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front & Rear Caliper Bolts . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5UH-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-E4458-00-00 Front Brake Lining / Rear Brake Lining . 3GD-W0045-00-00 / 5VH-WF536-00-00 Headlight Bulb / Taillight Bulb . . . . . . . . 5FU-H4314-00-00 / 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 3FV-83517-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-17641-00-00 4 Stroke Oil . . . . . . ACC-Y4020-40-12 (20W40) / ACC-Y4010-30-12 (10W30) 4Stroke Oil. . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Throttle Cable / Speedometer Cable . . . 5GH-26311-01-00 / 5VH-H3550-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5VH-F6331-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5KM-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

June 2009

YFM35FAService Data

2004~2006“Bruin 4WD”

(5UH)

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . Air Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 83 x 64.5mm (3.27 x 2.54 in) Number Cylinders / Displacement. . . . . . . . . . . . 1 / 348.9cc (21.29 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.3 L (2.4 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.2 L (2.3 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . 128.8 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . P-2M / 5ETY1-54 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 2 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (0.51 in) Fuel Level . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gask. Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 13.5L (3.6 US gal) / 3.0L (0.87 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L (0.24 US qt) Front Drive Type . . . . . . . . . . . . . . . Gear Drive / 2WD, 4WD Limited Slip - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.35L (0.37 US qt)

SUSPENSIoN:


TIRES:


YFM35FA 2004~2006 “Bruin 4WD” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω

CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX14AH System Maximum Output . . . . . . . . . . . . . . . . . . 14V 16A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω

LIGHTING SYSTEM:

Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front & Rear Caliper Bolts . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5UH-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-E4458-00-00 Front Brake Lining / Rear Brake Lining . 3GD-W0045-00-00 / 5VH-WF536-00-00 Headlight Bulb / Taillight Bulb . . . . . . . . 5FU-H4314-00-00 / 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 3FV-83517-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-17641-00-00 4 Stroke Oil . . . . . . ACC-Y4020-40-12 (20W40) / ACC-Y4010-30-12 (10W30) 4Stroke Oil. . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Throttle Cable / Speedometer Cable . . . 5GH-26311-01-00 / 5VH-H3550-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5VH-F6331-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5KM-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 83 x 64.5mm (3.27 x 2.54 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 348.9cc (21.29 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.2L (2.3 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 128.8 / 17.5 Air Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-2M / 5ETY2 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (.51 in) Fuel Level . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gasket Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 13.5L (3.6 US gal) / 3.3L (0.87 US gal) Fuel Type . . . . . . . . . . . . . . Premium Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.00 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)

June 2009

YFM35FGService Data

2007~“Grizzly 350 4WD”

(5UH)

YFM35FG 2007~ “Grizzly 350 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G/ 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX14AH System Maximum Output . . . . . . . . . . . . . . . . . . 14V 16A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front & Rear Caliper Bolts . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5UH-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-E4458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 5VH-WF536-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 5FU-H4314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 3FV-83517-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-17641-00-00 4 Stroke Oil . . . . . . ACC-Y4020-40-12 (20W40) / ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Throttle Cable / Speedometer . . . . . . . 5GH-26311-01-00 / 5VH-H3550-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5VH-F6331-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5KM-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 83 x 64.5mm (3.27 x 2.54 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 348.9cc (21.29 cu. in) Valve Clearance (cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.2L (2.3 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 128.8 / 17.5 Air Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-2M / 5ETY3 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (.51 in) Fuel Level . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gasket Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 13.5L (3.6 US gal) / 3.3L (0.87 US gal) Fuel Type . . . . . . . . . . . . . . Premium Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.00 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:


June 2009

YFM35FGIService Data

2007~“Grizzly 350 4WD IRS”

(4S2)

YFM35FGI 2007~ “Grizzly 350 4WD IRS” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX14AH System Maximum Output . . . . . . . . . . . . . . . . . . 14V 16A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W-21W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M12: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front & Rear Caliper Bolts . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5UH-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-E4458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 5FU-H4314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 3FV-83517-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 90201-12172-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-17641-00-00 4 Stroke Oil . . . . . . ACC-Y4020-40-12 (20W40) / ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX14-AH-BS Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26311-01-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5VH-F6331-00-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 5VH-H3550-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 4S2-26341-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5KM-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 83 x 64.5mm (3.27 x 2.54 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 348.9cc (21.29 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.2L (2.3 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . 128.8 / 17.5 Air Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-2M / 5ETY2 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (.51 in) Fuel Level . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gasket Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 13.5L (3.6 US gal) / 3.3L (0.87 US gal) Fuel Type . . . . . . . . . . . . . . Premium Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.00 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:


June 2009

YFM35GService Data


(5WH)

YFM35G 2007~ “Grizzly 350 2WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX14AH System Maximum Output . . . . . . . . . . . . . . . . . . 14V 16A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front & Rear Caliper Bolts . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5UH-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-E4458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 5VH-WF536-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 5FU-H4314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 3FV-83517-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-17641-00-00 4 Stroke Oil . . . . . . .ACC-Y4020-40-12 (20W40) / ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Throttle Cable / Speedometer . . . . . . . . 5GH-26311-01-00 / 5VH-H3550-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5VH-F6331-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5KM-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled 4 Cycle, SOHCBore x Stroke . . . . . . . . . . . . . . . . . . . 83.0 x 64.5mm (3.27 x 2.54 in)Number Cylinders / Displacement . . . . . . . . . . . . 1 / 349cc (21.30 cu. in)Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in)Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . Yamalube 4, 20W50Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40Oil Type - Below 0°C (32°F). . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30Capacity - Oil & Filter Change . . . . . . . . . . . . . . . . . 2.20L (2.33 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . 2.30L (2.43 US qt))

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single CarburetorManufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33Main Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . 128.8 / 17.5Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-2M / 5ETY3Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / N/AFloat Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (0.51 in)Fuel Level . . . . . . . . . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) AboveIdle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpmSet CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0%Fuel Tank Capacity - Main / Reserve . . 14.5L (3.83 US gal) / 4.5L (1.19 US gal)Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . Constant Mesh, Semi-Automatic Clutch, 5 Speed with 1 ReverseOil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE

FINAL DRIVE:


SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 5mm (0.0 ~ 0.2 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT23 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)

June 2009

YFM35XService Data

2006~“Wolverine 350 2WD”

(3D5)

YFM35X 2006~ “Wolverine 350 2WD” Service Data

IGNITIoN SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDISpark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EASpark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in)Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩIgnition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩPickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561ΩRotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.104 ~ 0.127ΩCHARGING SYSTEM:Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . AC MagnetoBattery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB12C-ASystem Maximum Output . . . . . . . . . . . . . . . . . . 14V 12A @ 3000 rpmStator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86ΩLIGHTING SYSTEM:Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30WTaillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5WIndicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4WToRqUE VALUES:Engine Drain Plug. . . . . . . . . . . . . . . . . . . . . M34: 3.2m-kg (23 ft-lb)Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb)Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 6.4m-kg (46 ft-lb)Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb)Rear Caliper Bolts. . . . . . . . . . . . . . . . . . . . . M10: 2.8m-kg (20 ft-lb)Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 6.4m-kg (46 ft-lb)Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)TUNE UP / MAINTENANCE PARTS:Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 1UY-13440-02-00Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1UY-14451-00-00Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14458-01-00Front Brake Lining. . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 1UY-W0046-00-00Headlight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-00-00Taillight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 123-83516-21-XXMain Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 2GV-82151-00-00 (20A)Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35512-00Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . 20W50 YamalubeOil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 YamalubeOil Type - Below 0°C (22°F) . . . . . . . . . . . . . . 5W40 or 5W30 YamalubeRear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB12C-A0-00Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-26311-10-00Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . 4KB-83550-00-00Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-2637E-02-00Front Brake Cable . . . . . . . . . . . . . . . . . . . . . . . 4KB-26351-01-00Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 4KB-26341-00-00Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 1UY-83922-01-00Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . 1UY-83912-01-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . Air Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 83.0 x 64.5mm (3.27 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 348cc (21.23 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°*C (32°F) . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 3.2 L (3.4 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (2.6 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . Mikuni / BTM32SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 / 45.0 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . N-8 / 5H26 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . 11.5 ~ 13.5mm (0.45 ~ 0.53 in) Fuel Level Measured From Gask Surface . . . . 1 ~ 2mm (0.04 ~ 0.08 in) Above Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . . 11L (2.9 US.gal) / 1.2L (0.32 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . Constant Mesh, Semi-Automatic Clutch, 5 Speed with 1 Reverse Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.25L(0.27 US qt) Front Drive Type . . . . . . . . . . . . . . . . . . . . . Gear Drive / Limited Slip - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.47L (0.49 US qt)

SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.00 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 12-9 - Nominal Pressure . . . . . . . . . . . . . 0.27 ~ 0.33 Kg/cm (3.5 ~ 4.7 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.17 ~ 0.23 Kg/cm (2.5 ~ 3.3 psi)

April 2005

YFM350ERService Data

1995“Moto-4”

(3HP)

YFM350ER 1995 “Moto-4” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, D8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . 0.357 ~ 0.483Ω / 5.44 ~ 7.36KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . Y ~ G / 171 ~ 209Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . Br ~ G / 270 ~ 330Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB14A-A1 System Maximum Output . . . . . . . . . . . . . . . . . . 14V 17A @ 3000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 25W-25W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.2m-kg (23 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M13: 13.0m-kg (94 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . . M13: 13.0m-kg (94 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-D8EA0-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1YW-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1YW-14458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4BD-W2536-01-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . 2HR ~ W0045-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 102-84314-00-XX Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-84714-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . 4R0-83517-00-00 12V/3.4 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35520-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 1UY-14147-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB14A-A1-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3HP-26311-10-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 1YW-26331-01-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 1YW-83550-00-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3HP-2637F-00-00 Front Brake Cable / Rear Brake Cable . . . 3GH-26361-01-00 / 1YW-26351-01-00 Front Brake Lever / Rear Brake Lever. . . . . . . . . . . 3GH-83922-10-00 / N/A

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . Air Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 83.0 x 64.5mm (3.27 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 348cc (21.23 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 3.0 L (3.2 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.9 L (3.1 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . Mikuni / BTM32SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 / 42.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Needle Jet / Jet Needle . . . . . . . . . . . . . P-0 / 4DP11 (CA. P-0M / 4DP16) Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 4 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in) Fuel Level Measured From Gask Surface . . . . . 2 ~ 3mm (0.08 ~ 0.12 in) Above Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . . 10L (2.6 US gal) / 1.3L (0.34 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.25L (0.27 US qt) Front Drive Type . . . . . . . . . . . . . . . . . . . . . Gear Drive / Limited Slip - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.47L (0.49 US qt)

SUSPENSIoN:


TIRES:


April 2005

YFM350FWService Data

1995~1996“Big Bear 4WD”

(3HN)

YFM350FW 1995~1996 “Big Bear 4WD” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, D8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . Br ~ G / 270 ~ 330Ω

CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB14A-A1 System Maximum Output . . . . . . . . . . . . . . . . . 14V 14.5A @ 3000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω

LIGHTING SYSTEM:

Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 25W-25W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.2m-kg (23 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M13: 13.0m-kg (94 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . . M13: 13.0m-kg (94 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-D8EA0-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1YW-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1YW-14458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3HN-W2535-10-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4WV-W2536-01-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 102-84314-00-XX Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-84714-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . 4R0-83517-00-00 12V/3.4 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35520-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB14A-A1-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3HN-26311-00-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 2HR-83550-01-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4GB-2637F-10-00 Front Brake Cable / Rear Brake Cable . . . . . . . . . . N/A / 3HN-26341-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 38W-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

April 2005

YFM350FWBService Data

1997~1999“Big Bear 4WD”

(5FT)

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 83.0 x 64.5mm (3.27 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 348cc (21.23 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 3.0 L (3.2 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.9 L (3.1 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . Mikuni / BTM32SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 / 42.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Needle Jet / Jet Needle . . . . . . . . . . . . . P-0 / 4DP11 (CA. P-0M / 4DP16) Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 4 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in) Fuel Level Measured From Gask Surface . . . . . 2 ~ 3mm (0.08 ~ 0.12 in) Above Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . . 10L (2.6 US gal) / 1.3L (0.34 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:


TIRES:


YFM350FWB 1997~1999 “Big Bear 4WD” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, D8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . Br ~ G / 270 ~ 330Ω

CHARGING SYSTEM:


LIGHTING SYSTEM:


ToRqUE VALUES:



Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-D8EA0-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1YW-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1YW-14458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3HN-W2535-10-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4WV-W2536-01-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 102-84314-00-XX Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-84714-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . 4R0-83517-00-00 12V/3.4 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35520-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB14A-A1-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3HN-26311-00-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 2HR-83550-01-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4GB-2637F-10-00 Front Brake Cable / Rear Brake Cable . . . . . . . . . . N/A / 3HN-26341-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 38W-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . Air Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 83.0 x 64.5mm (3.27 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 348cc (21.23 cu. in) Valve Clearance Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.8L (3.0 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.4L (2.5 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . Mikuni / BTM32SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 / 45.0 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . N-8 / 5H26 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . 11.5 ~ 13.5mm (0.45 ~ 0.53 in) Fuel Level Measured From Gask Surface . . . . 1 ~ 2mm (0.04 ~ 0.08 in) Above Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . . 10L (2.6 US gal) / 1.3L (0.34 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN


TIRES:


April 2005

YFM350FWJService Data

1997“Big Bear SE 4WD”

(4WU)

YFM350FWJ 1997 “Big Bear SE 4WD” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, D8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . (0.357 ~ 0.483) Ω / 5.44 ~ 7.36KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . R ~ W / 459 ~ 561Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . Br ~ G / 270 ~ 330Ω

CHARGING SYSTEM:


LIGHTING SYSTEM:


ToRqUE VALUES:



Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-D8EA0-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1YW-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1YW-14458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W2535-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4WV-W2536-01-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 102-84314-00-XX Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-84714-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . 4R0-83517-00-00 12V/3.4 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1 AE-82151-00-00 (30A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35520-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB14A-A1-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3HN-26311-00-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 2HR-83550-01-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4GB-2637F-10-00 Front Brake Cable / Rear Brake Cable . . . . . . . . . . N/A / 3HN-26341-00-00 Front Brake Lever / Rear Brake Lever. . . . 38W-83922-00-00 / 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 83 x 64.5mm (3.27 x 2.54 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 349cc (21.30 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 3.0L (3.2 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.9L (3.1 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BST34 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . 141.3 / 42.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-OM / 5H65 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . 1 ~ 2mm (0.04 ~ 0.08 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 - 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . 13.0L (3.4 US gal) / 1.7L (0.45 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Speed Semi-Automatic Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.19L (0.20 US qt) Front Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive, 4WD LSD - Oil Type . . . . . . . . . . . . SAE 80 API “GL-5” Hypoid Gear Oil For LSD - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.18L (0.19 US qt)

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 5mm (0.0 ~ 0.20 in) - Spring Preload (Std) . . . . . . . . . 2nd Position (From The Softest Setting) Rear - Spring Preload (Std) . . . . . . . . 2nd Position (From The Softest Setting)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . . . . 22 ~ 28kPa (3.2 ~ 4.1 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT23 x 10-12 - Nominal Pressure . . . . . . . . . . . . . . . . 22 ~ 28kPa (3.2 ~ 4.1 psi)

June 2009

YFM35FXService Data

1995~2005“Wolverine 4WD”

(4KB) (2D4)

YFM35FX 1995~2005 “Wolverine 4WD” Service Data

IGNITIoN SYSTEM:


CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB12C-A System Maximum Output . . . . . . . . . . . . . . . . . . 14V 12A @ 3000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω

LIGHTING SYSTEM:


ToRqUE VALUES:



Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Oil Filter O Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 93210-54452-00 Air Filter Type & Part Number . . . . . . . . . . . . Washable / 1UY-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14458-01-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 1UY-W0046-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 2GV-82151-00-00 (20A) Drain Bolt 0 Ring . . . . . . . . . . . . . . . . . . . . . . . . . 93210-35512-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (5W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB12C-A0-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-26311-10-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 4KB-26341-00-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 4KB-83550-00-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-2637E-02-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 83.0 x 64.5mm (3.27 x 2.54 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 349cc (21.30 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.5L (2.6 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . . 2.L (2.5 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR36 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . 142.5 / 22.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . P-0M / 5JFC39 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 2 / N/A Float Height . . . . . . . . . . . . . . . . . . . . 11.4 ~ 13.4mm (0.45 ~ 0.53 in) Fuel Level Measured From Gask Surface . . . . . 2 ~ 3mm (0.08 ~ 0.12 in) Below Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ~ 4.5% Fuel Tank Capacity - Main / Reserve . . . . 9.0L (2.4 US gal) / 1.9L (0.5 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . Constant Mesh, Manual Clutch, 6 Speed with 1 Reverse Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain Drive - Chain Free Playh . . . . . . . . . . . . . . . . 25 ~ 35mm (0.98 ~ 1.38 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 98 - Drive Sprocket Teeth / Driven Sprocket Teeth . . . . . . . . . . . . . 13 / 38

SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . 228.5mm (9.0 in)

TIRES:


April 2005

YFM350RService Data

2004~“Raptor 350”

(5YT)

YFM350R 2004~ “Raptor 350” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, D8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.024 ~ 0.028 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . R ~ W/L / 0.270 ~ 0.330Ω

CHARGING SYSTEM:


LIGHTING SYSTEM:

Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-12V 5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.2m-kg (23 ft-lb) Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Front Hub Nuts / Rear . . . . . . M14: 8.5m-kg (61 ft-lb) / M16: 12.0m-kg (85 ft-lb) Front Caliper Bolts / Rear . . . . . M8: 2.8m-kg (20 ft-lb) / M8: 2.3 m-kg (17 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1UY-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14458-01-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 1UY-W0046-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 3GY-82151-00-00 (15A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35512-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 5YT-14190-25-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTZ10-S0-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5YT-26311-00-00 Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 5YT-26311-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5LP-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . Air Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 83.0 x 64.5mm (3.27 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 348cc (21.23 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 3.0 L (3.2 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.9 L (3.1 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BST34 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 / 42.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Needle Jet / Jet Needle . . . . . . . . . . . . . P-0 / 4DP11 (CA. P-0M / 4DP16) Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 4 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in) Fuel Level Measured From Gask Surface . . . . . 2 ~ 3mm (0.08 ~ 0.12 in) Above Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . . 10L (2.6 US gal) / 1.3L (0.34 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN


TIRES:


April 2005

YFM350UService Data

1996~1999“Big Bear 2WD”

(5FE)

YFM350U 1996~1999 “Big Bear 2WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, D8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . R ~ W / 459 ~ 561Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . Br ~ G / 270 ~ 330Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB14A-A1 System Maximum Output . . . . . . . . . . . . . . . . . 14V 14.5A @ 3000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 25W-25W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W


TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-D8EA0-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1YW-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1YW-14458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3HN-W2535-10-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4WV-W2536-01-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 102-84314-00-XX Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-84714-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . 4R0-83517-00-00 12V/3.4 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35520-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 1UY-14147-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB14A-A1-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3HN-26311-00-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 2HR-83550-01-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4GB-2637F-10-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3HN-26341-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 38W-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 83 x 64.5mm (3.27 x 2.54 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 349cc (21.30 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.5L (2.6 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.4L (2.5 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . Mikuni / BTM36SH Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 / 42.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Needle Jet / Jet Needle . . . . . . . . . . . . . . . 0.6 / 5J18 (CA. 0-6M / 5J31) Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . 3 / N/A (CA. 1 / N/A) Float Height . . . . . . . . . . . . . . . . . . . . 11.4 ~ 13.4mm (0.45 ~ 0.53 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . 2 ~ 3mm (0.08 ~ 0.12 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 - 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . . 9.0L (2.4 US gal) / 1.9L (0.5 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Speed Manual Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain - Chain Free Play . . . . . . . . . . . . . . . . . 30 ~ 40mm (1.18 ~ 1.57 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 98 - Drive Sprocket Teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - Driven Sprocket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . 17 ~ 27mm (0.67 ~ 1.06 in) - Spring Preload (Std) . . . . . . . . . 1st Position (From The Softest Setting) Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . 228.5mm (9.0 in) - Damping (Std) . . . . . . . . . 15 Clicks (From The Fully Turned In Position)

TIRES:


June 2009

YFM350XService Data

1995~2004“Warrior”

(5NF)

YFM350X 1995~2004 “Warrior” Service Data

IGNITIoN SYSTEM:


CHARGING SYSTEM:


LIGHTING SYSTEM:


ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M34: 3.2m-kg (23 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M14: 8.5m-kg (61 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb) Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 12.0m-kg (85 ft-lb) Rear Axle Nut (See Service Manual for Procedure). . . M38: 24.0m-kg (170 ft-lb)


Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Oil Filter O Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 93210-54452-00 Air Filter Type & Part Number . . . . . . . . . . . . Washable / 1UY-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14458-01-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 1UY-W0046-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-82151-00-00 (15A) Drain Bolt 0 Ring . . . . . . . . . . . . . . . . . . . . . . . . . 93210-35512-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-25-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (5W30) Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB12C-A0-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-26311-01-00 Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-26335-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 1UY-26341-02-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5LP-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5LP-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled, 2 Stroke Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 64 x 54mm (2.52 x 2.13 in) Number Cylinders / Displacement . . . . . . . . . . . . 2 / 347cc (21.20 cu. in) Oil Type (Premix) / Ratio . . . . . . . . . . . . . . . . . . . Yamalube 2R / 24:1

CooLING SYSTEM:

Coolant Type. . . Ethylene Glycol With Corrosion Inhibitor For Aluminum Engines Coolant Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1 Coolant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 1.5L (1.6 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Mikuni / VM26SS Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 / 25 Air Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 / 5N7 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / 2.0 Float Height . . . . . . . . . . . . . . . . . . . . 20.5 ~ 21.5mm (0.81 ~ 0.85 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . 0.5 ~ 1.5mm (0.02 ~ 0.06 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 - 1550 rpm Fuel Tank Capacity - Main / Reserve . . . 12.0L (3.2 US gal) / 2.5L (0.7 US gal) Fuel Type / Octane . . . . . . . . . Premium Unleaded / ([R+M]/2) 90 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Speed Manual Oil Type / Capacity . . . . . . . . . . . . . Yamalube 4, 10W30 / 1.5L (1.6 US qt)

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain - Chain Free Play . . . . . . . . . . . . . . . . . . . . . . . 15mm (0.60 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 104 - Drive Sprocket Teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - Driven Sprocket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . 3rd Position (From The Softest Setting) Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . 220.5mm (7.7 in) - Compression Damping (Std) . . 10 Clicks (From The Fully Turned Out Position) - Rebound Damping (Std) . . . . 10 Clicks (From The Fully Turned In Position)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT21 x 7-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . . . 30kPa (4.4 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT20 x 10-9 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . . . 30kPa (4.4 psi)

June 2009

YFZ350Service Data

1995~2006“Banshee”

(5FK)

YFZ350 1995~2006 “Banshee” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, B8ES Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.7 ~ 0.8mm (0.028 ~ 0.031 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 1.44 ~ 1.76Ω / 5.28 ~ 7.92KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . W/R ~ W/G / 94 ~ 140Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . G ~ R / 13.7 ~ 20.5Ω

LIGHTING SYSTEM:

System Maximum Output . . . . . . . . . . . . . . . . . . . 16.3V @ 8000 rpm Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . Y ~ B / 0.26 ~ 0.38Ω Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . 12V 21W-12V 5W

ToRqUE VALUES:

Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 2.0m-kg (14 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M14: 2.0m-kg (14 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M14: 8.5m-kg (61 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20 ft-lb) Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 12.0m-kg (87 ft-lb) Rear Axle Nut (See Service Manual for Procedure). . . M38: 24.0m-kg (170 ft-lb)


Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-B8ES0-00-00 Air Filter Type & Part Number . . . . . . . . . . . . Washable / 2GU-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5FK-14458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 1UY-W0046-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 90430-14043-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UA-14190-28-00 Float Bowl Gasket . . . . . . . . . . . . . . . . . . . . . . . . 304-14184-00-00 2 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . ACC-Y2R00-00-12 Transmission Oil . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 2GU-26260-01-00 Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 2GU-26335-01-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 1UY-26361-02-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5LP-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5LP-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 84.5 x 71.5mm (3.33 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 401cc (24.47 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15*C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.4L (2.5 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt)

CooLING SYSTEM:

Coolant Type. . Ethylene Glycol With Corrosion Inhibitors For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 1.1L (1.16 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . 132.5 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP13-55 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (.51 in) Fuel Level . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gasket Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 15.0L (3.9 US gal) / 4.5L (1.19 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:


TIRES:


June 2009

YFM4AService Data

2003~2004“Kodiak 2WD”

(5VH)

YFM4A 2003~2004 “Kodiak 2WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap / Spark Plug Cap Ω . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) / 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX14AH System Maximum Output . . . . . . . . . . . . . . . . . . 14V 12A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front / Rear Caliper Bolts . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5ND-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5ND-E4458-00-00 Front Brake Lining / Rear Brake Lining. . . . . 3GD-W0045-00-00 / 5VH-WF536-00-00 Headlight / Taillight Bulb . . . . . . . . . . 5FU-H4314-00-00 / 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-17641-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX14-AH-LB Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5GH-26331-02-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 5VH-H3550-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5VH-F6331-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5KM-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE: Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 84.5 x 71.5mm (3.33 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 401cc (24.47 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.4L (2.5 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt)

CooLING SYSTEM: Coolant Type. . . Ethylene Glycol With Corrosion Inhibitors For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 1.1 L (1.16 US qt)

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . 132.5 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP13-55 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (.51 in) Fuel Level . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gasket Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 15.0L (3.9 US gal) / 4.5L (1.19 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN: Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic With Reverse Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE

FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L (0.24 US qt) Front Drive Type . . . . . . . . . . . . . . . Gear Drive / 2WD, 4WD Limited Slip - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.35L (0.37 US qt)

SUSPENSIoN: Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1psi)

April 2005

YFM4FAService Data

2003~2004“Kodiak 4WD”

(5TE)

YFM4FA 2003~2004 “Kodiak 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap / Spark Plug Cap Ω . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) / 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX14AH System Maximum Output . . . . . . . . . . . . . . . . . . 14V 12A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front / Rear Caliper Bolts . . . . . . M8: 3.0m-kg (22 ft-lb) / M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5ND-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5ND-E4458-00-00 Front Brake Lining / Rear Brake Lining . 3GD-W0045-00-00 / 5VH-WF536-00-00 Headlight Bulb / Taillight Bulb . . . . . . . . 5FU-H4314-00-00 / 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-17641-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil / Rear Gear Case Oil . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX14-AH-LB Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5GH-26331-02-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 5VH-H3550-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5VH-F6331-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5KM-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

June 2009

YFM4FAService Data

2005~2008“Kodiak 4WD”

(1P1)

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 84.5 x 75.0mm (3.33 x 2.95 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 420cc (25.67 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15*C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.4L (2.5 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . . 2.L (2.4 US qt)

CooLING SYSTEM:

Coolant Type. . Ethylene Glycol With Corrosion Inhibitors For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 1.3L (1.37 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.3 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP13-55 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (0.51 in) Fuel Level . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gasket Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 15.0L (3.9 US gal) / 4.5L (1.19 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic With Reverse Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE V-Belt Width / Limit . . . . . . . . . . . . . . 30.7mm (1.21 in) / 27.6mm (1.09 in)

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L (0.24 US qt) Front Drive Type . . . . . . Gear Drive / 2WD, 4WD Limited Slip & 4WD Locking - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L (0.24 US qt)

SUSPENSIoN:


TIRES:



IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type / Spark Plug Gap . . . . NGK, DR8EA / 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 19A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front & Rear Caliper Bolts . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5ND-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-E4458-00-00 Front Brake Lining / Rear Brake Lining. . . . . 3GD-W0045-00-00 / 5GH-W0046-10-00 Headlight / Taillight Bulb . . . . . . . . . . 5FU-H4314-00-00 / 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-17641-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5VH-F6331-00-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 5VH-H3550-00-00 Front Brake Lever / Rear . . . . . . . . . 5KM-83922-00-00 / 5GH-26341-01-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 83 x 71.5mm (3.27 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 386cc (23.55 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 3.0L (3.2 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.9L (3.1 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.5 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP4-55 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 - 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . 15.0L (3.9 US gal) / 4.0L (1.06 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . 2nd Position (From The Softest Setting) Rear - Spring Preload (Std) . . . . . . . . 2nd Position (From The Softest Setting)

TIRES:


April 2005

YFM40Service Data

2000~2004“Big Bear 2WD”

(5GW)

YFM40 2000~2004 “Big Bear 2WD” Service Data

IGNITIoN SYSTEM:


CHARGING SYSTEM:

Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 15A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω

LIGHTING SYSTEM:


ToRqUE VALUES:



Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Oil Filter O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 93210-54452-00 Air Filter Type & Part Number . . . . . . . . . . . Disposable / 4XE-E4450-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 5FU-WF536-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5FU-H4314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 36Y-82151-00-00 (15A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 42X-82151-00-00 (10A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35520-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (5W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5FU-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5FU-26331-10-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5FU-26341-00-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-2637E-02-00

ENGINE:


FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.5 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP4-55 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 - 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . 15.0L (3.9 US gal) / 4.0L (1.06 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L (0.24 US qt) Front Drive Type . . . . . . . . . . . . . . . . . . . . Gear Drive, 2WD-4WD LSD - Oil Type . . . . . . . . . . . . SAE 80 API “GL-5” Hypoid Gear Oil For LSD - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.35L (0.37 US qt)

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . 2nd Position (From The Softest Setting) Rear - Spring Preload (Std) . . . . . . . . 2nd Position (From The Softest Setting)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . . . . 22 ~ 28kPa (3.2 ~ 4.1 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . . . . 22 ~ 28kPa (3.2 ~ 4.1 psi)

June 2009

YFM40FService Data

2000~2006“Big Bear 4WD”

(5FU)

YFM40F 2000~2006 “Big Bear 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.024 ~ 0.028 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.104 ~ 0.127Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 15A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . 12V 21W-12V 5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.2m-kg (23 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) TUNE UP / MAINTENANCE PARTS: Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Oil Filter O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 93210-54452-00 Air Filter Type & Part Number . . . . . . . . . . . Disposable / 4XE-E4450-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 5FU-WF536-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5FU-H4314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 36Y-82151-00-00 (15A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 42X-82151-00-00 (10A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35520-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (5W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5FU-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5FU-26331-10-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 4WV-83550-00-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-2637E-02-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5FU-26341-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . . . Air Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 83.0 x 71.5mm (3.27 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 387cc (23.55 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5˚C (40˚F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15˚C (60˚F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0˚C (32˚F) . . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 3.0L (3.2 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.9L (3.1 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.5 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP9-55 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in) Fuel Level . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gask. Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . 15.0L (3.96 US gal) / 4.0L (1.06 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . Yamaha Friction Modified Shaft Drive Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.50L (0.53 US qt) Front Drive Type . . . . . . . Gear Drive / 2WD 4WD Limited Slip & 4WD Locking - Oil Type . . . . . . . . . . . Yamaha Friction Modified Shaft Drive Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L (0.24 US qt)

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . 5 ~ 15mm (0.20 ~ 0.59 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-1 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi

June 2009

YFM40FBService Data

2007~“Big Bear 400 IRS”

(4S1)

YFM40FB 2007~ “Big Bear 400 IRS” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.104 ~ 0.127Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 15A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W-21W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.2m-kg (23 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Paper / 4XE-E4450-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 5FU-H4314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A) - Additional Fuse . . . . . . . . . . . . . . . . . . . .36Y-82151-00-00 (15A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 42X-82151-00-00 (10A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35520-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . .ACC-Y4ATV-53-12 (5W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5FU-26311-00-00 Starter able (Choke) . . . . . . . . . . . . . . . . . . . . . . . 5FU-26331-10-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 4WV-83550-00-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-2637E-02-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . 4S1-26341-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 84.5 x 71.5mm (3.33 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 401cc (24.47 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.4L (2.5 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt)

CooLING SYSTEM:

Coolant Type . . . . Ethylene Glycol With Corrosion Inhibitors For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . 1 :1 / 1.1 L (1.14 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . 132.5 / 17.5 (CA. 130 / 17.5) Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . P-0M / 5EP7-55 (CA. P-0M / 5EP11-55) Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (.51 in) Fuel Level Measured From Gask Surface . . . . . 2 ~ 3mm (0.08 ~ 0.12 in) Above Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . . 15L (3.9 US gal) / 4.5L (1.19 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . -10 ~ 10mm (-0.39 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 kg/cm (3.2 ~ 4.0 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 kg/cm (3.2 ~ 4.0 psi)

April 2005

YFM400AService Data

2000~2001“Kodiak 2WD”

(5HA)


IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.104 ~ 0.127Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 12A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.0m-kg (22 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front / Rear Caliper Bolts . . . . . . M8: 3.0m-kg (22 ft-lb) / M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1UY-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14458-01-00 Front Brake Lining / Rear Brake Lining . . 3GD-W0045-00-00 / 5GH-W0046-10-00 Headlight Bulb / Taillight Bulb . . . . . . . . 4KB-84314-00-00 / 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 123-83516-21-XX Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35512-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-17641-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5GH-26331-02-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 5GH-83550-00-00 Rear Brake Cable / Front Brake Lever . . 5GH-26341-01-00 / 5GH-83922-00-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

June 2009

YFM400FService Data

1995~1999“Kodiak 4WD”

(5EH) (4SH) (4GB)

ENGINE:


FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BST34 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . 112.5 / 42.5 (CA. 115 / 42.5) Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . P-0M / 4DHY13 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in) Fuel Level Measured From Gask Surface . . . . . 1 ~ 2mm (0.04 ~0.08 in) Above Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . . 13.5L (3.6 US gal) / 1.3L (0.3 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . 0.19 L (0.20 US qt) Front Drive Type . . . . . . . . . . . . . . . . . . . . . Gear Drive / Limited Slip - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . 0.18 L (0.19 US qt)

SUSPENSIoN:


TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.0 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.0 psi)

YFM400F 1995~1999 “Kodiak 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, D8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.36 ~ 0.48Ω / 5.44 ~ 7.36KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . R ~ W / 171 ~ 209Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . Br ~ G / 270 ~ 330Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 17A @ 3000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W / 12V 1.7W


TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-D8EA0-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 1UY-13440-02-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1YW-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1YW-14458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 4WV-W2536-01-00 Front Brake Pad Kit (1999 5EH). . . . . . . . . . . . . . . . . 3GD-W0045-01-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-84714-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . 3GM-83517-00-00 12V/1.7W Indicator Bulb . . . . . . . . . . . . . . . . . . . . . 4R0-83517-00-00 12V / 3.4 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35520-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4WU-26311-00-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 5EH-83550-00-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-2637E-01-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 4WU-26341-00-00 Front Brake Lever / Rear Brake Lever. . . . 38W-83922-00-00 / 2HT-83912-00-00

April 2005

YFM400FAService Data

2000~2002“Kodiak 4WD”

(5GH)

ENGINE: Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 84.5 x 71.5mm (3.33 x 2.81 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 401cc (24.47 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.4L (2.5 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt)

CooLING SYSTEM: Coolant Type. . Ethylene Glycol With Corrosion Inhibitors For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 1.1 L (1.14 US qt)

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . 132.5 / 17.5 (CA. 130 / 17.5) Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . P-0M / 5EP7-55 (CA. P-0M / 5EP11-55) Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (0.51 in) Fuel Level Measured From Gask Surface . . . . . 2 ~ 3mm (0.08 ~ 0.12 in) Above Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0 Fuel Tank Capacity - Main / Reserve . . . . 15L (3.9 US gal) / 4.5L (1.19 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN: Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic With Reverse Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE V-Belt Width / Limit . . . . . . . . . . . . . . 29.3mm (1.15 in) / 27.3mm (1.07 in)

FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.19L (0.20 US qt) Front Drive Type . . . . . . . . . . . . . . . Gear Drive / 2WD, 4WD Limited Slip - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . 0.35 L (0.37 US qt)

SUSPENSIoN: Front - Toe In . . . . . . . . . . . . . . . . . . . . -10 ~ 10mm (-0.39 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 kg/cm (3.2 ~ 4.0 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 kg/cm (3.2 ~ 4.0 psi)

YFM400FA 2000~2002 “Kodiak 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap / Spark Plug Cap Ω . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) / 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.104 ~ 0.127Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 12A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.0m-kg (22 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front Caliper Bolts / Rear Caliper Bolts. . . M8: 3.0m-kg (22 ft-lb) / M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1UY-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14458-01-00 Front Brake Lining / Rear Brake Lining . 3GD-W0045-00-00 / 5GH-W0046-10-00 Headlight Bulb / Taillight Bulb . . . . . . . . 4KB-84314-00-00 / 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 123-83516-21-XX Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35512-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-17641-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5GH-26331-02-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 5GH-83550-00-00 Front Brake Cable / Rear Brake Cable . . . . . . . . . . N/A / 5GH-26341-01-00 Front Brake Lever / Rear Brake Lever. . . 5GH-83922-00-00 / 2HT-83912-00-00

April 2005

YFM45FAService Data

2003~2004“Kodiak 450 4WD”

(5ND)


CooLING SYSTEM: Coolant Type. . Ethylene Glycol With Corrosion Inhibitors For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . 1:1 / 1.3 L (1.37 US qt)

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.3 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP13-55 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (.51 in) Fuel Level . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gasket Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 15.0L (3.9 US gal) / 4.5L (1.19 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher


FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L (0.24 US qt) Front Drive Type . . . . . . Gear Drive / 2WD, 4WD Limited Slip & 4WD Locking - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L(0.24 US qt)

SUSPENSIoN: Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ .39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1psi)

YFM45FA 2003~2004 “Kodiak 450 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 12A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front / Rear Caliper Bolts . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5ND-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5ND-E4458-00-00 Front / Rear Brake Lining . . . . . . . . 3GD-W0045-00-00 / 5GH-W0046-10-00 Headlight Bulb / Taillight Bulb . . . . . . . . 5FU-H4314-00-00 / 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 . FUSE (30A-BL) - Additional Fuse . . . . . . . . . . . . . . 5JJ-82151-10-00 FUSE (15A-BL) - Additional Fuse . . . . . . . . . . . . . . 5JJ-82151-30-00 FUSE (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . 5JJ-82151-50-00 FUSE (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-17641-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5GH-26331-02-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26341-01-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5KM-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00


CooLING SYSTEM: Coolant Type. . . Ethylene Glycol With Corrosion Inhibitors For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 1.3L (1.37 US qt)

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.3 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP13-55 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (0.51 in) Fuel Level . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gasket Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . . 15.0L (3.9 US gal) / 4.5L (1.19 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher


FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L (0.24 US qt) Front Drive Type . . . . . . Gear Drive / 2WD, 4WD Limited Slip & 4WD Locking - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L(0.24 US qt)

SUSPENSIoN: Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)

June 2009

YFM45FAService Data

2005~2007“Kodiak 450 4WD” “Grizzly 450 4WD”

(1D9)

YFM45FA 2005~2007 “Kodiak 450 4WD” “Grizzly 450 4WD”

Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 19A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front & Rear Hub Nuts . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front & Rear Caliper Bolts . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5UH-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-E4458-00-00 Front / Rear Brake Lining . . . . . . . . 3GD-W0045-00-00 / 1D9-W0046-00-00 Headlight Bulb / Taillight Bulb . . . . . . . . 5FU-H4314-00-00 / 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-17641-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26311-01-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5VH-F6331-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26341-01-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5KM-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

June 2009

YFM45FGService Data


(17S)

ENGINE: Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 84.5 x 75.0mm (3.33 x 2.95 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 420cc (25.67 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.06 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W50 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.4L (2.5 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt)

CooLING SYSTEM: Coolant Type. . . Ethylene Glycol With Corrosion Inhibitors For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 1.3L (1.37 US qt)

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.3 / 17.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP19 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (0.51 in) Fuel Level . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gask. Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . 15.0L (3.9 US gal) / 4.5L (1.19 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher


FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . Yamaha Friction Modified Shaft Drive Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.50L (0.53 US qt) Front Drive Type . . . . . . . Gear Drive / 2WD, 4WD Limited Slip & 4WD Locking - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L (0.24 US qt)

SUSPENSIoN: Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . .0 ~ 10mm (0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)

YFM45FG 2008~ “Grizzly 450 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EA Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 19A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M20: 26.0m-kg (190 ft-lb) TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5ND-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5ND-E4458-00-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 5GH-W0046-10-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 5FU-H4314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-17641-00-00 Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . . 20W50 Yamalube Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 Yamalube Oil Type - Below 0°C (22°F) . . . . . . . . . . . . . . . 5W40 or 5W30 Yamalube Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5GH-26331-02-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26341-01-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . 5KM-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

June 2009

YFM45FXService Data

2006~“Wolverine 450 Sport 4WD”

(3C2)

ENGINE:Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHCBore x Stroke . . . . . . . . . . . . . . . . . . . . 84.5 x 75mm (3.33 x 2.95 in)Number Cylinders / Displacement . . . . . . . . . . . . 1 / 420cc (25.67 cu. in)Valve Clearance (Cold) - Intake . . . . . . . . 0.60 ~ 0.10mm (0.0024 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in)Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . Yamalube 4, 20W50Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40Oil Type - Below 0°C (32°F). . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30Capacity - Oil & Filter Change . . . . . . . . . . . . . . . . . . 2.4L (2.5 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt)

CooLING SYSTEM:Coolant Type . . Ethylene Glycol with Corrosion Inhibitors for Aluminum EnginesCoolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 1.3L (1.37 US qt)

FUEL SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single CarburetorManufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33Main Jet / Pilot Jet / Pilot Screw (Turns Out) . . . . . . . . . . . 131.3 / 17.5 / 1.5Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP19Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / N/AFloat Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (.51 in)Fuel Level . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gasket SurfaceIdle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpmSet CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ~ 5%Fuel Tank Capacity - Main / Reserve . . . 15.0L (3.9 US gal) / 4.5L (1.19 US gal)Fuel Type . . . . . . . . . . . . . Unleaded Regular / ( [R+M] / 2 ) 86 or Higher

TRANSMISSIoN:Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic with ReverseOil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / øV-Belt Width / Limit . . . . . . . . . . . . . . 30.7mm (1.12 in) / 27.6mm (1.09 in)

FINAL DRIVE:Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive Live Axle - Oil Type SAE. . . . . . . . . . . . . . . . . . 80 API GL-4 Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.23L (0.24 US qt)Front Drive Type . . . . . . Gear Drive / 2WD, 4WD Limited Slip & 4WD Locking - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API GL-4 Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.35L (0.37 US qt)

SUSPENSIoN:Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT23 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.37 ~ 0.43Kg/cm (5.0 ~ 6.0 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT23 x 10-12 - Nominal Pressure . . . . . . . . . . . . . 0.37 ~ 0.43 Kg/cm (5.0 ~ 6.0 psi)

YFM45FX 2006~ “Wolverine 450 Sport 4WD” Service Data

IGNITIoN SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDISpark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EASpark Plug Gap . . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.02 ~ 0.03 in)Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩIgnition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩPickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561ΩRotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.085 ~ 0.105ΩCHARGING SYSTEM:Charging System Type . . . . . . . . . . . . . . . . . . . . . . . A/C MagnetoMaximum Output . . . . . . . . . . . . . . . . . . . . . . 14V 19A @ 5000 rpmBattery - Manufacturer / Model . . . . . . . . . . . . . . . . . . . ø / YTX20L-BSStator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62ΩLIGHTING SYSTEM:Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30WTaillight / Indicator . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W / LED

ToRqUE VALUES:Drain Plug, Engine . . . . . . . . . . . . . . . . . . . . . M8: 2.3m-kg (17 ft-lb)Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb)Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb)Rear Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb)Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS:Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5UG-E4451-00-00Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5UG-E4458-00-00Front Brake Lining. . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . 5GH-W0046-00-00Headlight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00Taillight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . 256-84714-60-00Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL)

- Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL)Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4SV-14107-20-00Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-17641-00-00Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . . 20W50 YamalubeOil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 YamalubeOil Type - Below 0°C (22°F). . . . . . . . . . . . . . . 5W40 or 5W30 YamalubeFront Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-26311-01-00Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 3C2-F6331-00-00Park Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 3C2-26341-00-00

June 2009

YFZ450Service Data

2004~2005“YFZ450”

(5TG)

ENGINE: Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 95 x 62mm (3.74 x 2.44 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 439cc (26.79 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.10 ~ 0.15mm (0.004 ~ 0.006 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.20 ~ 0.25mm (0.008 ~ 0.010 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . 1.85L (1.96 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 1.75L (1.85 US qt)

CooLING SYSTEM: Coolant Type. . . Ethylene Glycol With Corrosion Inhibitors For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . . 1:1 / 1.3L (1.4 US qt)

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Keihin / FCR39H Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 / 42 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . NA / NDS4 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 4 / 1.5 Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8mm (0.31 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 ~ 1850 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 ~ 6.0% Fuel Tank Capacity - Main / Reserve . . 10.0L (2.64 US gal) / 1.9L (0.50 US gal) Fuel Type . . . . . . . . . . . . . . Premium Unleaded / ([R+M]/2) 91 or Higher

TRANSMISSIoN: Type . . . . . . . . . . . . . . . . . . . Constant Mesh, Manual Clutch, 5 Speed Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE

FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain drive - Chain Free Play . . . . . . . . . . . . . . . . . 25 ~ 35mm (0.98 ~ 1.38 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 96 - Drive Sprocket Teeth / Driven Sprocket Teeth . . . . . . . . . . . . . 14 / 38

SUSPENSIoN: Front - Toe In . . . . . . . . . . . . . . . . . . . . . 2 ~ 12mm (0.08 ~ 0.47 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . 255mm (10.04 in) - Compression Damping (Std). . 11 Clicks (From The Fully Turned In Position) - Rebound Damping (Std) . . . . 12 Clicks (From The Fully Turned In Position) Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . 244mm (9.61 in) - Compression Damping (Std) 1 3/4 turns (From The Fully Turned In Position) - Rebound Damping (Std) . . . 1 3/4 turns (From The Fully Turned In Position)

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AT21 x 7-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.30 Kg/cm (4.4 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT20 x 10-9 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.35 Kg/cm (5.0 psi)

YFZ450 2004~2005 Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR8E Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.7 ~ 0.8mm (0.028 ~ 0.031 in) Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.08 ~ 0.10Ω / 4.56 ~ 6.84KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . W ~ R / 248 ~ 372Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GT7B-4 System Maximum Output . . . . . . . . . . . . . . . . . 14V 8.6A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . W ~ Ground / 0.29 ~ 0.43Ω LIGHTING SYSTEM: Lighting Coil Color Code / Ω . . . . . . . . . . . . . Y ~ Ground / 0.22 ~ 0.34Ω Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14 ft-lb) Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . M10: 2.7m-kg (19 ft-lb) Rear Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . M8: 3.1m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . . M14: 12.0m-kg (85 ft-lb) Rear Axle Nuts (See Service Manual For Procedure). . . M46: 10.0m-kg (72 ft-lb) Rear Axle Bearing Hub Nuts . . . . . . . . . . . . . . . . M14 8.5m-kg (61 ft-lb) Chain Adjuster Lock Nuts . . . . . . . . . . . . . . . . . . M8: 1.6m-kg (11.0 ft-lb) Drive Sprocket Nuts . . . . . . . . . . . . . . . . . . . . . M18: 7.5m-kg (54 ft-lb) Driven Sprocket Nuts . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)

TUNE UP / MAINTENANCE PARTS Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR8E-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 5TA-13440-00-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5TG-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5TG-14458-00-00 Front Brake Lining / Rear Brake Lining . . 5TG-W0045-00-00 / 5LP-W0046-50-00 Headlight Bulb / Taillight Bulb . . . . . . . . 4KB-84314-01-00 / 256-84714-61-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 36Y-82151-00-00 (15A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 90430-10148-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4MX-14392-00-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5JG-14984-00-00 4 Stroke Oil . . . . . . ACC-Y4020-40-12 (20W40) / ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4UC-82100-01-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5TG-26311-00-00 Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 5TG-26335-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5TG-26341-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5TG-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 5TJ-83912-00-00

June 2009

YFZ450Service Data

2006~“YFZ450”

(5TG) (5D3)

ENGINE:Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHCBore x Stroke . . . . . . . . . . . . . . . . . . . . 95 x 63.4mm (3.74 x 2.50 in)Number Cylinders / Displacement . . . . . . . . . . . . . 1 / 449cc (27.4 cu. in)Valve Clearance (Cold) - Intake . . . . . . . . . 0.10 ~ 0.15mm (0.004 ~ 0.006 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.20 ~ 0.25mm (0.008 ~ 0.010 in)Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . Yamalube 4, 20W50Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40Oil Type - Below 0°C (32°F). . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30Capacity - Oil & Filter Change . . . . . . . . . . . . . . . . . 1.85L (1.96 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 1.75L (1.85 US qt)

CooLING SYSTEM:Coolant Type . . . Ethylene Glycol With Corrosion Inhibitors For Aluminum EnginesCoolant Ratio / Capacity . . . . . . . . . . . . . . . . . . . 1:1 / 1.3L (1.4 US qt)

FUEL SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single CarburetorManufacturer / Model . . . . . . . . . . . . . . . . . . . . . . Keihin / FCR39HMain Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 / 42Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . NA / NGNRClip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / 1.5Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8mm (0.31 in)Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 ~ 1850 rpmSet CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 ~ 6.5%Fuel Tank Capacity - Main / Reserve . . 10.0L (2.649 US gal) / 1.9L (0.50 US gal)Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 91 or Higher

TRANSMISSIoN:Type . . . . . . . . . . . . . . . . . . . Constant Mesh, Manual Clutch, 5 SpeedOil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE

FINAL DRIVE:Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain Drive - Chain Free Play . . . . . . . . . . . . . . . . . 25 ~ 35mm (0.98 ~ 1.38 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 96 - Drive sprocket Teeth / Driven Sprocket Teeth . . . . . . . . . . . . . 14 / 38

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . . 2 ~ 12mm (0.08 ~ 0.47) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . 255mm (10.04 in) - Compression Damping (Std). . 11 Clicks (From The Fully Turned In Position) - Rebound Damping (Std) . . . . 12 Clicks (From The Fully Turned In Position)Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . 244mm (9.61 in) - Compression Damping (Std) 1-3/4 Turns (From The Fully Turned In Position) - Rebound Damping (Std) . . . 1-3/4Turns (From The Fully Turned In Position)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT21 x 7-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.30 Kg/cm (4.4 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT20 x 10-9 - Nominal Pressure . . . . . . . . . . . . . . . . . . . 0.235 Kg/cm (5.0 psi)

YFZ450 2006~ “YFZ450” Service Data

IGNITIoN SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDISpark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR8ESpark Plug Gap . . . . . . . . . . . . . . . . . . 0.7 ~ 0.8mm (0.028 ~ 0.031 in)Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.08 ~ 0.10Ω / 4.56 ~ 6.84KΩPickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . W ~ R / 248 ~ 372ΩCHARGING SYSTEM:Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . AC MagnetoBattery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GT7B-4System Maximum Output . . . . . . . . . . . . . . . . . 14V 8.6A @ 5000 rpmStator Coil Color Code / Ω . . . . . . . . . . . . . . W ~ Ground / 0.29 ~ 0.43ΩLIGHTING SYSTEM:Lighting Coil Color Code / Ω . . . . . . . . . . . . . . Y-Ground / 0.22 ~ 0.34ΩHeadlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30WTaillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5WIndicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7WToRqUE VALUES:Engine Drain Plug. . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14 ft-lb)Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14 ft-lb)Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb)Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb)Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb)Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . M10: 2.7m-kg (19 ft-lb)Rear Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.1m-kg (22 ft-lb)Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb)Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M14: 12.0m-kg (85 ft-lb)Rear Axle Nuts (See Service Manual For Procedure) . . M46: 10.0m-kg (72 ft-lb)Rear Axle Bearing Hub Nuts . . . . . . . . . . . . . . . . M14 8.5m-kg (61 ft-lb)Chain Adjuster Lock Nuts . . . . . . . . . . . . . . . . . . M8: 1.6m-kg (11.0 ft-lb)Drive Sprocket Nuts . . . . . . . . . . . . . . . . . . . . . M8: 1.6m-kg (11.0 ft-lb)Driven Sprocket Nuts . . . . . . . . . . . . . . . . . . . . M18: 7.5m-kg (54 ft-lb)TUNE UP / MAINTENANCE PARTS:Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR8E0-00-00Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 5TA-13440-00-00Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5TG-14451-00-00Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5TG-14458-00-00Front Brake Lining. . . . . . . . . . . . . . . . . . . . . . . 5TG-W0045-00-00Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 5LP-W0046-50-00Headlight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00Taillight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . 256-84714-61-00Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 36Y-82151-00-00 (15A)Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 90430-10148-00Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4MX-14392-00-00Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5JG-14984-00-00Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . . 20W50 YamalubeOil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 YamalubeOil Type - Below 0°C (22°F). . . . . . . . . . . . . . . 5W40 or 5W30 YamalubeBattery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4UC-82100-01-00Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5TG-26311-00-00Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 5TG-26335-00-00Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5TG-26341-00-00Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5TG-83922-00-00Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 5TG-83912-00-00

June 2009

YFZ450RService Data

2009~“YFZ450R”

(18P)

ENGINE:Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, DOHCBore x Stroke . . . . . . . . . . . . . . . . . . . . 95 x 63.4mm (3.74 x 2.50 in)Number Cylinders / Displacement . . . . . . . . . . . . . 1 / 449cc (27.4 cu. in)Valve Clearance (Cold) - Intake . . . . . . . . . 0.10 ~ 0.15mm (0.004 ~ 0.006 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.20 ~ 0.25mm (0.008 ~ 0.010 in)Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . Yamalube 4, 20W50Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40Oil Type - Below 0°C (32°F). . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30Capacity - Oil & Filter Change . . . . . . . . . . . . . . . . . 1.45L (1.53 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 1.40L (1.48 US qt)

CooLING SYSTEM:Coolant Type . . . . Ethylene Glycol With Corrosion Inhibitors For Aluminum EnginesCoolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 1.25L (1.4 US qt)

FUEL SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel InjectionManufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / 42EHSMain Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/APilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/ANeedle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AClip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . N/AFloat Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AIdle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1950 ~ 2050 rpmSet CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ~ 9.0%Fuel Tank Capacity - Main / Reserve . . . 10.0 L (2.64 US gal) / 3.4 L (0.90 US gal)Fuel Type . . . . . . . . . . . . . . Premium Unleaded / ([R+M]/2) 91 or Higher

TRANSMISSIoN:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Constant Mesh, 5 SpeedOil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE

FINAL DRIVE:Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain Drive - Chain Free Play . . . . . . . . . . . . . . . . . 25 ~ 35mm (0.98 ~ 1.38 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 98 - Drive Sprocket Teeth / Driven Sprocket Teeth . . . . . . . . . . . . . 14 / 38

SUSPENSIoN:Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . 2 ~ 12mm (0.08 ~ 0.47) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . 289.8mm (11.41 in) - Compression Damping (Std) Lo / Hi . . . . . . . . . . 10 Clicks (1 Turn Out) - Rebound Damping (Std) . . . . . . . . . . . . . . . . . . . . 12 Clicks OutRear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . 265.0mm (10.43 in) - Compression Damping (Std) Lo / Hi . . . . . . . . 8 Clicks Out / 1 Turn Out - Rebound Damping (Std) . . . . . . . . . . . . . . . . . . . . 11 Clicks Out

TIRES:Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT21 x 7R10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . 0.275 Kg/cm (4.0 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT20 x 10R9 - Nominal Pressure . . . . . . . . . . . . . . . . . . . 0.300 Kg/cm (4.4 psi)

YFZ450R 2009~ “YFZ450R” Service Data

IGNITIoN SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TCI-DigitalSpark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR8ESpark Plug Gap . . . . . . . . . . . . . . . . . . 0.7 ~ 0.8mm (0.028 ~ 0.031 in)Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩIgnition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)Primary Ω / Secondary Ω . . . . . . . . . . . . . 2.16 ~ 2.64Ω / 8.64 ~ 12.96KΩPickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . W ~ R / 248 ~ 372ΩCHARGING SYSTEM:Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . AC MagnetoBattery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTZ-7SSystem Maximum Output . . . . . . . . . . . . . . . 14.0V 265 W @ 5000 rpmStator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.32 ~ 0.48ΩLIGHTING SYSTEM:Lighting Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . . . . . N/AHeadlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30WTaillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEDIndicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED

ToRqUE VALUES:Engine Drain Plug. . . . . . . . . . . . . . . . . . . . . M10: 2.0m-kg (14 ft-lb)Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . M10: 2.0m-kg (14 ft-lb)Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb)Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb)Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M14: 7.0 m-kg (50 ft-lb)Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . M8: 2.8 m-kg (20 ft-lb)Rear Caliper Bolts. . . . . . . . . . . . . . . . . . . . . M10: 4.3 m-kg (31 ft-lb)Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb)Rear Hub Nuts (See Service Manual) . . . . . . . . . . M16: 20 m-kg (145 ft-lb)Rear Axle Nuts (See Service Manual For Procedure) . . M38: 25 m-kg (181 ft-lb)Rear Axle Nut Set Screws. . . . . . . . . . . . . . . . . M6: 0.7 m-kg (5.1 ft-lb)Rear Axle Pinch Bolts (See Service Manual For Procedure). . . M8: 2.1 m-kg (15 ft-lb)Drive Sprocket Nut . . . . . . . . . . . . . . . . . . . . M22: 10 m-kg (72 ft-lb)Driven Sprocket Nuts . . . . . . . . . . . . . . . . . . . . M8: 7.2 m-kg (52 ft-lb)

TUNE UP / MAINTENANCE SPARTS:Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR8E0-00-00Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 5D3-13440-00-00Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5TG-14451-00-00Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5TG-14458-00-00Front Brake Lining. . . . . . . . . . . . 5TG-W0045-20-00 / 5TG-W0045-30-00Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 5TG-W0046-10-00Headlight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00Taillight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-84710-01-00Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 2GH-82151-00-00 (20A)Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 90430-10148-004 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yamlube 20W504 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . Yamalube 10W404 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . Yamalube 5W30 / 5W40Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTZ7S-HE-00Battery Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 18P-82122-00-00Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 18P-26311-00-00Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5D3-83922-00-00Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 5TJ-83912-00-00

ENGINE: Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . 92.0 x 84.0mm (3.62 x 3.31 in) Number Cylinders / Displacement. . . . . . . . . . . . . .1 / 558cc (34.05 cu. in) Valve Clearance (Cold) - Intake . . . . . . . .0.09 ~ 0.13mm (0.0035 ~ 0.0051 in) - Exhaust . . . . . . . . . . . . . . . 0.160 ~ 0.200mm (0.0063 ~ 0.0079 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W50 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . 2.10L (2.22 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 2.00L (2.11 US qt)

CooLING SYSTEM: Coolant Type. . . Ethylene Glycol With Corrosion Inhibitors For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . 1:1 / 1.99L (2.10 US qt)

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . . Mikuni / 40EIS Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . 1N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 ~ 1650 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4% Fuel Tank Capacity - Main / Reserve . . . . 20L (5.3 US gal) / 4.5L (1.19 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN: Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic with Reverse Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE V-Belt Width / Limit . . . . . . . . . . . . . . . 33.3mm (1.31 in) / 30mm (1.18 in)

FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.20L (0.21 US qt) Front Drive Type . . . . . . . . . . . Gear Drive / 2WD, 4WD LSD-4WD Locking - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.22L (0.23 US qt)

SUSPENSIoN: Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.35 kgf/cm (5.0 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.30 kgf/cm (4.4 psi)

June 2009

YFM5FG/PService Data

2009~“Grizzly 550 FI 4WD/EPS”

(28P) (34D)

YFM5FG/P 2009~ “Grizzly 550 FI 4WD/EPS” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TCI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . NGK, LMAR6A-9 Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.8 ~ 0.9mm (0.031 ~0.035 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . . 3.4 ~ 4.6Ω / 10.4 ~ 15.6KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . Gy ~ B / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . N/A

CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . 14V 34A @ 5000 RPM Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . W ~ W / 0.108 ~ 0.132Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 35/35W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5/21W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.0 m-kg (22 ft-lb) Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3 m-kg (9.4 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5 m-kg (40 ft-lb) Front Hub Nut (See Service Manual) . . . . . . . . . . . M20: 26 m-kg (190 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.0 m-kg (22 ft-lb) Rear Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . M8: 3.0 m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5 m-kg (40 ft-lb)R ear Hub Nuts (See Service Manual) . . . . . . . . . . M20: 26 m-kg (190 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-LMAR6-A9-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-20-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 3B4-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-14472-00-00 Front Brake Lining . . . . . . . . . . . . . 3B4-W0045-00-00 / 3B4-W0045-10-00 Rear Brake Lining . . . . . . . . . . . . . 3B4-W0046-00-00 / 3B4-W0046-10-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 5PS-82151-00-00 (40A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A) - Additional Fuse . . . . . . . . . . . . . . . . . . . . 5JJ-82151-90-00 (5A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28P-17641-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (20W50) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (10W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . (05W30 / 05W40) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-26311-20-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-2637F-10-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 3B4-83922-00-00 Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 3B4-83912-00 -00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 95 x 84mm (3.74 x 3.31 in) Number Cylinders / Displacement. . . . . . . . . . . . . . . 595cc (36.33 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.05 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.12 ~ 0.17mm (0.005 ~ 0.007 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . 2.0L (2.11 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 1.9L (2.01 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BST40 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . 143.8 / 42.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . Y-0M / 6HH28-94 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7mm (0.58 in) Fuel Level . . . . . . . . . . . . . . . . . . . 2.0 ~ 3.0mm (0.08 ~ 0.12 in) Above Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350 ~ 1450 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 6.0% Fuel Tank Capacity - Main / Reserve . . . . . 19L (5.02 US gal) 3L (0.79 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . -5 ~ 5mm (-0.2 ~ 0.2 in) Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:


April 2005


1998“Grizzly 4WD”

(4MV)

YFM600FA 1998 “Grizzly 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DPR8EA-9 Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.8 ~ 0.9mm (0.03 ~ 0.04 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . R ~ W / 459 ~ 561Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . BR ~ G / 270 ~ 330Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 12A @ 3000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front / Rear Caliper Bolts . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . . Cartridge / 4X7-13440-01-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1UY-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14458-01-00 Front Brake Lining / Rear Brake Lining . 4WV-W0045-00-00 / 4WV-W2536-01-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-84714-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . 4G1-84744-00-XX 12V/3.4W Indicator Bulb . . . . . . . . . . . . . . . . . . . . 3GM-83517-00-00 12V/1.7W Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 2GV-82151-00-00 (20A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 42X-82151-00-00 (10A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4WV-14190-28-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 4WV-14147-20-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4WV-17641-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil / Rear Gear Case Oil . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4WV-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 4WV-26331-00-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 4WV-83550-00-00 Rear Brake Cable / Front Brake Lever . . . 4WV-26341-00-00 / 1RX-83922-01-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooler 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 95 x 84mm (3.74 x 3.31 in) Number Cylinders / Displacement. . . . . . . . . . . . . . . 595cc (36.33 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.05 ~ 0.10mm (0.002 ~ 0.004 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.12 ~ 0.17mm (0.005 ~ 0.007 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . 2.0L (2.11 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 1.9L (2.01 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BST40 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . 143.8 / 42.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . Y-0M / 6HH28-94 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7mm (0.58 in) Fuel Level . . . . . . . . . . . . . . . . . . . 2.0 ~ 3.0mm (0.08 ~ 0.12 in) Above Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350 ~ 1450 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 6.0% Fuel Tank Capacity - Main / Reserve . . . . . 19L (5.02 US gal) 3L (0.79 US gal) Fuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:


FINAL DRIVE:


SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . -5 ~ 5mm (-0.2 ~ 0.2 in) Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:


April 2005


1999~2001“Grizzly 4WD”

(5GT)

YFM600FA 1999~2001 “Grizzly 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DPR8EA-9 Spark Plug Gap . . . . . . . . . . . . . . . . . . . 0.8 ~ 0.9mm (0.03 ~ 0.04 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . R ~ W / 459 ~ 561Ω Source Coil Color Code / Ω . . . . . . . . . . . . . . . . . BR ~ G / 270 ~ 330Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 12A @ 3000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.70 ~ 0.86Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 2.3m-kg (17 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb) Front / Rear Caliper Bolts . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00 Oil Filter Type / Part Number . . . . . . . . . . . . . Cartridge / 4X7-13440-01-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 1UY-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14458-01-00 Front Brake Lining / Rear Brake Lining . . . 4WV-W0045-00-00 / 4WV-W2536-01-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GD-84714-00-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . 4G1-84744-00-XX 12V/3.4W Indicator Bulb . . . . . . . . . . . . . . . . . . . . 3GM-83517-00-00 12V/1.7W Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 2GV-82151-00-00 (20A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 42X-82151-00-00 (10A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 4WV-14190-28-00 Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 4WV-14147-20-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4WV-17641-00-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (05W30) Front Differential Oil / Rear Gear Case Oil . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4WV-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 4WV-26331-00-00 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 4WV-83550-00-00 Rear Brake Cable / Front Brake Lever . . . 4WV-26341-00-00 / 1RX-83922-01-00 Rear Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00

ENGINE: Engine Type . . . . . . . . . . . . . . . . . . . . Liquid Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 100 x 84mm (3.94 x 3.31 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 659cc (40.26 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.10 ~ 0.15mm (0.004 ~ 0.006 in) - Exhaust . . . . . . . . . . . . . . . . . 0.15 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.0L (2.1 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 1.9L (2.0 US qt)

CooLING SYSTEM: Coolant Type. . . Ethylene Glycol With Corrosion Inhibitor For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . . 1:1 / 1.8L (1.9 US qt)

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR42 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.8 / 40 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . O-0M / 6JPH-10 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (.51 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5mm (.14 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 - 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ~ 5.5% Fuel Tank Capacity - Main / Reserve . . . 20.0L (5.3 US gal) / 3.5L (0.92 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø V-Belt Width / Limit . . . . . . . . . . . . . . 33.2mm (1.31 in) / 29.9mm (1.18 in)

FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.25L (0.26 US qt) Front Drive Type . . . . . . . . . . . . Gear Drive, 2WD-4WD LSD-4WD Locking - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.28L (0.30 US qt)

SUSPENSIoN: Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . 2nd Position (From The Softest Setting) Rear - Spring Preload (Std) . . . . . . . . 2nd Position (From The Softest Setting)

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . . . . 32 ~ 38kPa (4.6 ~ 5.5 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . . . . 27 ~ 33kPa (3.9 ~ 4.8 psi)

June 2009

YFM660FService Data

2002~2008“Grizzly 660 4WD”

(5KM) (2C6) (23D)

YFM660F 2002~2008 “Grizzly 660 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DPR8EA-9 Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.8 ~ 0.9mm (0.031 ~ 0.035 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.104 ~ 0.127Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX20L-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 21A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.32 ~ 0.43Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . 12V 21W-12V 5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . . M14: 3.0m-kg (22 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 20.0m-kg (145 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . M16: 20.0m-kg (145 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DPR8E-A9-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type & Part Number . . . . . . . . . . . . Washable / 1UY-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14458-01-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 4WV-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 5KM-W0046-00-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 5KM-14190-30-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5KM-17641-00-00 Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . . 20W50 Yamalube Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 Yamalube Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . 5W40 or 5W30 Yamalube Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5KM-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5KM-26331-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . Liquid Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 100 x 84mm (3.94 x 3.31 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 659cc (40.26 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.10 ~ 0.15mm (0.004 ~ 0.006 in) - Exhaust . . . . . . . . . . . . . . . . . 0.15 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . 1.95L (2.1 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 1.9L (2.06 US qt)

CooLING SYSTEM:

Coolant Type. . . Ethylene Glycol With Corrosion Inhibitor For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . . 1:1 / 1.3L (1.4 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . L:140 R:145 / L&R 22.5 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . LH 3.5 / RH 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . P-6M / 5ND16-56 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 3 / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (0.51 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 - 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 ~ 5.0% Fuel Tank Capacity - Main / Reserve . . 12.0L (3.17 US gal) / 2.6L (0.69 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Speed, Manual Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain - Chain Free Play . . . . . . . . . . . . . . . . . 30 ~ 45mm (1.18 ~ 1.77 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 92 - Drive Sprocket Teeth / Driven Sprocket Teeth . . . . . . . . . . . . . 13 / 40

SUSPENSIoN:

Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . 3rd Position (From The Softest Setting) Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . 253mm (9.96 in) - Compression Damping (Std) . . . . 7 Clicks (From The Fully Turned In Position) - Rebound Damping (Std) . . . 10 Clicks (From The Fully Turned Out Position)

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT21 x 7-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . . . 27.5kPa (4.0 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT20 x 10-9 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . . . 27.5kPa (4.0 psi)

June 2009

YFM660RService Data

2001~2005“660R Raptor”

(5LP)

YFM660R 2001~2005 “660R Raptor” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DPR8EA-9 Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.8 ~ 0.9mm (0.031 ~ 0.035 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 445 ~ 545Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.069 ~ 0.085Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTX14-BS System Maximum Output . . . . . . . . . . . . . . . . . . 14V 16A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.43 ~ 0.65Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . 12V 21W-12V 5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.0m-kg (22 ft-lb) Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . M14: 2.5m-kg (18 ft-lb) Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M16: 7.0m-kg (50 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 12.0m-kg (85 ft-lb) Rear Axle Nut (See Service Manual for Procedure). . . M38: 24.0m-kg (170 ft-lb) Rear Caliper Bolts . . . . . . . . . . . . . . . . . . . . . M10: 2.8m-kg (20 ft-lb) TUNE UP / MAINTENANCE PARTS: Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DPR8E-A9-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . Spin On / 5DM-13440-00-00 Air Filter Type & Part Number . . . . . . . . . . . . Washable / 5LP-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5LP-14458-01-00 Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 5LP-W0045-00-00 Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 5LP-W0046-50-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 256-84714-61-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 2GV-82151-00-00 (20A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 5LP-14107-20-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94581-18092-00 Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . 9383E-13216-00 Driven Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . 2XJ-25440-20-00 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (5W30) Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX14-BS-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5LP-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5LP-26331-10-00 Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 5LP-26335-00-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5LP-26341-00-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5LP-26150-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 102 x 84mm (4.02 x 3.31 in) Number Cylinders / Displacement . . . . . . . . . . . . 1 / 686cc (41.86 cu. in) Valve Clearance (Cold) - Intake . . . . . . . 0.09 ~ 0.13mm (0.0035 ~ 0.0051 in) - Exhaust . . . . . . . . . . . . . . . 0.160 ~ 0.200mm (0.0063 ~ 0.0079 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W50 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . 2.10L (2.22 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 2.00L (2.11 US qt)

CooLING SYSTEM:

Coolant Type. . . Ethylene Glycol with Corrosion Inhibitors for Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . 1:1 / 1.99L (2.10 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / 44EHS Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 ~ 1650 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0% Fuel Tank Capacity - Main / Reserve . . . . 20L (5.3 US gal) / 4.5L (1.19 US gal) Fuel Type . . . . . . . . . . . . . . Unleaded Regular ( [R+M] / 2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic with Reserve Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø V-Belt Width / Limit . . . . . . . . . . . . . . 31.7mm (1.25 in) / 31.3mm (1.23 in)

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live” Axle - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.20L (0.21 US qt)Front Drive Type . . . . . . Gear Drive / 2WD, 4WD Limited Slip & 4WD Locking - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.22L (0.23 US qt)

SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ 0.39 in) - Spring Preload (Sted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . . . . 0.32 ~ 0.38 kgf/cm (5-6 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . . . . 0.27 ~ 0.33 kgf/cm (4-5 psi)

June 2009


2007~2008“Grizzly 700 FI/EPS”

(5C0) (3B4)

YFM7FG/P 2007~2008 “Grizzly 700 FI/EPS” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TCI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CPR7EA-9 Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.8 ~ 0.9mm (0.031 ~ 0.035 in) Spark Plug Cap Resistance Ω . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil - Test Gap . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . . 3.4 ~ 4.6Ω / 13.0KΩ ± 20% Pickup Coil - Color Code / Ω . . . . . . . . . . . . . . . . . Gy ~ B / 459~561Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . A/C Magneto Maximum Output . . . . . . . . . . . . . . . . . . . . . 14V 33.5A @ 5000 rpm Battery - Manufacturer / Model . . . . . . . . . . . . . . . . . . . ø / YTX20L-BS Stator Coil - Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.13 ~ 0.15Ω LIGHTING SYSTEM: Headlight / Taillight / Indicator . . . . . . . . . . 12V 35/35W / 12V 5/21W / LED ToRqUE VALUES: Drain Plug, Engine . . . . . . . . . . . . . . . . . . . . M14: 3.0m-kg (22 ft-lb) Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M20: 26m-kg (190 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb) Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb) Rear Hub Nuts. . . . . . . . . . . . . . . . . . . . . . . M20: 26m-kg (190 ft-lb) TUNE UP / MAINTENANCE PARTS: Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CPR7E-A9-00 Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-20-00 Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 3B4-14451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-14472-00-00 Front Brake Lining . . . . . . . . . . . . 3B4-W0045-00-00 / 3B4-W0045-10-00 Rear Brake Lining . . . . . . . . . . . . . 3B4-W0046-00-00 / 3B4-W0046-10-00 Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-84314-00-00 Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 5PS-82151-00-00 (40A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A) - Additional Fuse. . . . . . . . . . . . . . . . . . . . . 5JJ-82151-90-00 (5A) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . N/A V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-17641-00-00 Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . . 20W50 Yamalube Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 Yamalube Oil Type - Below 0°C (22°F) . . . . . . . . . . . . . . . 5W40 or 5W30 Yamalube Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-26311-00-00 Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-2637F-00-00 Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 3B4-83922-00-00 Rear Brake Or Clutch Lever . . . . . . . . . . . . . . . . . . . 3B4-83912-00-00

ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHCBore x Stroke . . . . . . . . . . . . . . . . . . . . 102 x 84mm (4.02 x 3.31 in)Number Cylinders / Displacement . . . . . . . . . . . . 1 / 686cc (41.86 cu. in)Valve Clearance (Cold) - Intake . . . . . . . 0.09 ~ 0.13mm (0.0035 ~ 0.0051 in) - Exhaust . . . . . . . . . . . . . . . 0.160 ~ 0.200mm (0.0063 ~ 0.0079 in)Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . Yamalube 4, 20W50Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40Oil Type - Below 0°C (32°F). . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30Capacity - Oil & Filter Change . . . . . . . . . . . . . . . . . 2.10L (2.22 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 2.00L (2.11 US qt)

CooLING SYSTEM:

Coolant Type . . Ethylene Glycol with Corrosion Inhibitors for Aluminum EnginesCoolant Ratio / Capacity . . . . . . . . . . . . . . . . . 1:1 / 1.99L (2.10 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel InjectionManufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . . Mikuni / 44EISIdle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 ~ 1650 rpmSet CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0%Fuel Tank Capacity - Main / Reserve . . . . 20L (5.3 US gal) / 4.5L (1.19 US gal)Fuel Type . . . . . . . . . . . . . . Unleaded Regular ( [R+M] / 2) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic with ReserveOil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / øV-Belt Width / Limit . . . . . . . . . . . . . . 31.7mm (1.25 in) / 31.3mm (1.23 in)

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle” - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.20L (0.21 US qt)Front Drive Type . . . . . . Gear Drive / 2WD, 4WD Limited Slip & 4WD Locking - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.22L (0.23 US qt)

SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ 0.39 in) - Spring Preload (Sted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . . . . 0.32 ~ 0.38 kgf/cm (5-6 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . . . . . 0.27 ~ 0.33 kgf/cm (4-5 psi)

June 2009


2009~“Grizzly 700 FI/EPS”

(5C0)(43P)

YFM7FG/P 2009~ “Grizzly 700 FI 4WD/EPS” Service Data

IGNITIoN SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TCISpark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . NGK, LMAR6A-9Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.8 ~ 0.9mm (0.031 ~ 0.035 in)Spark Plug Cap Resistance Ω . . . . . . . . . . . . . . . . . . . . . . . 10KΩIgnition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)Primary Ω / Secondary Ω . . . . . . . . . . . . . . . 3.4 ~ 4.6Ω / 13.0KΩ ± 20%Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . Gy ~ B / 459 ~ 561ΩCHARGING SYSTEM:Charging System Type . . . . . . . . . . . . . . . . . . . . . . . A/C MagnetoMaximum Output . . . . . . . . . . . . . . . . . . . . . 14V 33.5A @ 5000 rpmBattery - Manufacturer / Model . . . . . . . . . . . . . . . . . . . ø / YTX20L-BSStator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.13 ~ 0.15ΩLIGHTING SYSTEM:Headlight / Taillight / Indicator . . . . . . . . . . 12V 35/35W / 12V 5/21W / LED

ToRqUE VALUES:Drain Plug, Engine . . . . . . . . . . . . . . . . . . . . M14: 3.0m-kg (22 ft-lb)Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/ASpark Plug . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb)Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M20: 26m-kg (190 ft-lb)Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb)Rear Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22 ft-lb)Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M20: 26m-kg (190 ft-lb)

TUNE UP / MAINTENANCE PARTS:Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-LMAR6-A9-00Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-20-00Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 3B4-14451-00-00Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-14472-00-00Front Brake Lining. . . . . . . . . . . . . 3B4-W0045-00-00 / 3B4-W0045-10-00Rear Brake Lining . . . . . . . . . . . . . 3B4-W0046-00-00 / 3B4-W0046-10-00Headlight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-84314-00-00Taillight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AMain Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 5PS-82151-00-00 (40A) - Additional Fuse . . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A) - Additional Fuse . . . . . . . . . . . . . . . . . . . . 5JJ-82151-90-00 (5A)Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AFloat Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . N/AV-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-17641-00-00Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . . 20W50 YamalubeOil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 YamalubeOil Type - Below 0°C (22°F). . . . . . . . . . . . . . . 5W40 or 5W30 YamalubeFront Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTX20-LB-S0Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-26311-20-00Reverse Cable. . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-2637F-10-00Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 3B4-83922-00-00Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 3B4-83912-00-00

ENGINE:Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHCBore x Stroke . . . . . . . . . . . . . . . . . . . . 102 x 84mm (4.02 x 3.31 in)Number Cylinders / Displacement . . . . . . . . . . . . 1 / 686cc (41.86 cu. in)Valve Clearance (Cold) - Intake . . . . . . . 0.09 ~ 0.13mm (0.0035 ~ 0.0051 in) - Exhaust . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.0063 ~ 0.0079 in)Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . Yamalube 4, 20W50Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40Oil Type - Below 0°C (32°F). . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30Capacity - Oil & Filter Change . . . . . . . . . . . . . . . . . 1.85L (1.96 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 1.75L (1.85 US qt)

CooLING SYSTEM:Coolant Type . . . . . Ethylene Glycol with Corrosion Inhibitors for Aluminum EnginesCoolant Ratio / Capacity . . . . . . . . . . . . . . . . . . . 1:1 / 1.6L (1.7 US qt)

FUEL SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel InjectionManufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / 44EHSMain Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/ANeedle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AClip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . N/AFloat Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AFuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AIdle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 ~ 1700 rpmSet CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 ~ 8.5%Fuel Tank Capacity - Main / Reserve . . . . . . . . . . . . . . 11L (2.91 US gal)Fuel Type . . . . . . . . . . . . . . Unleaded Regular ( [R+M] / 2) 86 or Higher

TRANSMISSIoN:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Speed ManualOil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / øV-Belt Width / Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A

FINAL DRIVE:Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain Drive - Chain Free Play . . . . . . . . . . . . . . . . . 25 ~ 35mm (0.98 ~ 1.38 in) - Chain Size / Links . . . . . . . . . . . . . . . . . . . . . . . . . . 520 / 98 - Drive Sprocket Teeth / Driven Sprocket Teeth . . . . . . . . . . . . . 14 / 38

SUSPENSIoN:Front - Toe In . . . . . . . . . . . . . . . . . . . 2.0 ~ 12.0mm (0.008 ~ 0.47 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . 260.0mm (10.24 in) - Compression Damping (Std) Lo / Hi . . . . . . . 10 Clicks Out / 2 Clicks Out - Rebound Damping (Std) . . . . . . . . . . . . . . . . . . . . 12 Clicks OutRear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . 233.0mm (9.17 in) - Compression Damping (Std). . . . . . . . . . . 11 Clicks Out / 2 Clicks Out - Rebound Damping (Std) . . . . . . . . . . . . . . . . . . . . 13 Clicks Out

TIRES:Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT21 x 7-10 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.27Kg/cm (4.0 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT20 x 10-9 - Nominal Pressure . . . . . . . . . . . . . . . . . . . . 0.27 Kg/cm (4.0 psi)

June 2009

YFM70RService Data

2006~“Raptor 700R”

(1S3)

YFM70R 2006~ “Raptor 700R” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TCI-DigitalISpark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR8ESpark Plug Gap . . . . . . . . . . . . . . . . . . 0.7 ~ 0.9mm (0.028 ~ 0.031 in)Spark Plug Cap Resistance Ω . . . . . . . . . . . . . . . . . . . . . . . 10KΩIgnition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)Primary Ω / Secondary Ω . . . . . . . . . . . . . . . 3.4 ~ 4.6Ω / 10.4 ~ 15.6KΩPickup Coil Color Code / Ω . . . . . . . . . . . . . . . L/Y ~ G/W / 192 ~ 288Ω

CHARGING SYSTEM:

Charging System Type . . . . . . . . . . . . . . . . . . . . . . . A/C MagnetoMaximum Output . . . . . . . . . . . . . . . . . . . . . 14V 17.2A @ 5000 rpmBattery - Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . ø / YT9-B4Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.24 ~ 0.37Ω

LIGHTING SYSTEM:

Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED

ToRqUE VALUES:

Drain Plug, Engine . . . . . . . . . . . . . . . . . . . . M14: 2.3m-kg (17 ft-lb)Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . . M8: 1.9m-kg (13 ft-lb)Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4 ft-lb)Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb)Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 7.0m-kg (50 ft-lb)Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . M10: 2.7m-kg (19 ft-lb)Rear Caliper Bolts. . . . . . . . . . . . . . . . . . . . . M10: 3.0m-kg (22 ft-lb)Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32 ft-lb)Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M16: 20m-kg (145 ft-lb)Rear Axle Nuts (See Service Manual for Procedure) . . . . M38: 24.0m-kg (175 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR8E0-00-00Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 4X7-13440-01-00Air Filter Type / Part Number . . . . . . . . . . . . Washable / 1S3-14451-00-00Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-14458-00-00Front Brake Lining / Rear Brake Lining . . 1S3-W0045-00-00 / 1S3-W0046-00-00Headlight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-84710-00-00Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 3FV-83517-00-00Main Fuse . . . . . . . . . . . . . . . . . . . . . . 2GH-82151-00-00 Fuse (20A)Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94582-13098-00Drive Sprocket. . . . . . . . . . . . . . . . . . . . . . . . . 9383G-14231-00-00Driven Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . 5TG-25438-10-00Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . . 20W50 YamalubeOil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 YamalubeOil Type - Below 0°C (22°F). . . . . . . . . . . . . . . 5W40 or 5W30 YamalubeBattery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YT9B4-00-00Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-26311-00-00Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AClutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-26335-00-00Reverse Cable. . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-26150-00-00

Side x SideService Data

2009 Side x SideData Sheet Reference

Model Market NameModelCode

2004(S)

2005(T)

2006(V)

2007(W)

2008(X)

2009(Y)

YXR45FA Rhino 450 4WD 2P5

YXR66F Rhino 660 4WD 5UG

YXP700A ProHauler 700 JW4

YXR70F Rhino 700 FI 5B4 / 42S

YXP1000A ProHauler 1000 JW5

Data Sheet Reference

SIDE BY SIDE 6/10/2009 SXS2009-006

SUBJECTS: 1. All Rhino Models – V-Belt Information


All Rhino Models – V-Belt InformationThe following information has been provided to better assist you when servicing the V-belt of a Rhino. The following V-belt chart is also available in the new Spec Data book.

Part NumberModel

ApplicationTop Width

“A” mm“A” Wear Limit mm

Thickness “B” mm

Angle “C” Degree

Outside Circumference

mm

5B4-17641-00-00 YXR70F (5B4, 42S) 32.7 30.0 15.8 + 0.6 27 + 1 944 + 3

5KM-17641-01-00 YXR66F (5UG) 32.7 30.0 14.9 + 0.6 26 + 1 944 + 3

5GH-17641-10-00 YXR45F (2P5) 28.3 27.3 13.6 + 0.6 28 + 1 876 + 3

NOTE: Although some V-belts share common dimensions, they cannot be interchanged because the construction material is specific to the application.

For easy Model Code cross reference, use the Starting PID Number reference pages listed in the Spec Data book.

SIDE X SIDE 12/22/08 SXS2008-005

ALL 2009 MODELSSide x Side Starting Primary I.D. Numbers

PAGE 1 of 1


Model Model Name Displacement Model Code Starting P. I.D. Number

YXR70FY Rhino 700 FI 686cc 5B4H AM16Y-0010401

YXR70FHY Rhino 700 FI Hunter (Realtree® AP HD® Camo) 686cc 5B4T AM18Y-0002701

YXR70FDUY Rhino 700 FI Ducks Unlimited® Edition 686cc 5B4M AM20Y-0000701

YXR70SPY Rhino 700 FI Sport Edition 686cc 5B4P AM21Y-0003001

YXR70FSEY Rhino 700 FI Special Edition 686cc 5B4W AM23Y-0002901

YXR70SP2Y Rhino 700 FI Sport Edition 2 686cc 42S1 AM24Y-0003601

YXR45FY Rhino 450 421cc 2P5G AJ32Y-0004001

YXR45FHY Rhino 450 Hunter (Realtree® AP HD® Camo) 421cc 2P5F AJ30Y-0001301

The following is a comprehensive listing of Primary ID numbers for 2009 Yamaha Side x Sides. The frame number of a unit contains the Primary ID for warranty purposes. Production started with the listed numbers below. The Model Code appears on a label on the SxS and is useful to help identify the model when contact-ing Yamaha Parts & Accessories. This code is also referenced with other model information at the beginning of the Parts List on CD-ROM.

YXR70FX Rhino 700 FI LIT-11626-21-58 LIT-11616-21-58 N/A N/A LIT-11666-21-58

YXR70FSPX Rhino 700 FI LIT-11626-21-59 LIT-11616-21-58 N/A N/A LIT-11666-21-58

Sport Edition

YXR70FSP2X Rhino 700 FI LIT-11626-21-65 LIT-11616-21-58 N/A N/A LIT-11666-21-58

Special Edition II

YXR70FSEPX Rhino 700 FI LIT-11626-21-58 LIT-11616-21-58 N/A N/A LIT-11666-21-58

Special Edition I

YXR70FHX Rhino 700 FI LIT-11626-21-58 LIT-11616-21-58 N/A N/A LIT-11666-21-58

Hunter Edition

YXR70FDUX Rhino 700 FI LIT-11626-21-58 LIT-11616-21-58 N/A N/A LIT-11666-21-58 Ducks Unlimited

YXR45FX Rhino 450 LIT-11626-21-21 YXR45FHW LIT-11616-21-21 LIT-11616-RH-46* LIT-11666-19-43 LIT-11616-RH-45*

YXR45FSPX Rhino 450 LIT-11626-21-21 YXR45FSEW LIT-11616-21-21 LIT-11616-RH-46* LIT-11666-19-43

Special Edition LIT-11616-RH-45*

YXR45FHX Rhino 450 Hunter LIT-11626-21-21 YXR45FHW LIT-11616-21-21 LIT-11616-RH-46* LIT-11666-19-43

LIT-11616-RH-45*

SIDE x SIDE 5/20/08 SXS2008-003C

2008 MODELSSide x Side Service Literature

PAGE 1 of 2



New ’08 Service Manual ’08 Supplement Compilation Manual Assembly Model Model Name Owner’s Manual (Main) (Supplements Only) (Main & Supplements) Manual

* The manual is a compilation of the related Service Manual and Supplements. This is the part number to order for a complete manual.

Effective 4/12/09, this Technical Bulletin replaces SXS2008-003B; please remove and destroy SXS2008-003B. An denotes a change.

PAGE 2 of 2

CATEGORY PUBLICATIONS PART NUMBER 2008 Rhino Product Brochure LIT-RHINO-66-Y8

2008 Rhino Basic Orientation Video 5B4-U595A-01-00

2008 Rhino Accessories and Apparel Brochure LIT-10080-RN-08

2005 and Earlier Side x Side Limited Warranty Statement* LIT-11790-05-03

2006 and Later Side x Side Limited Warranty Statement* LIT-11790-65-06

Side x Side Dealer Setup & Predelivery Checklist LIT-17561-00-07

2008 ATV/SxS Technical Update Book LIT-17500-AT-08

2001~2005 Technical Update DVD LIT-175MT-R5-DV

2007 SxS Service Manuals CD LIT-CDSRV-SS-07

Heavy Duty Service Binder LIT-10501-01-80

Service Schedule Pad LIT-11561-00-96

Warranty & Y.E.S. Handbook LIT-11760-00-05

SXS Drop-off Inspection Form LIT-INSPC-FM-SX

2008 SxS Flat Rate Manual LIT-17750-SS-08

Warranty Labor Rate Change Request LIT-11791-02-02

Parts System Handbook LIT-10080-07-04

Y.E.S. Plan Highlights - Motorsports LIT-11580-00-05

Y.E.S. Sample Contract LIT-11580-00-38

Y.E.S. Registration Card LIT-11580-00-04

Y.E.S. Used Hang Tag LIT-11580-00-40

Y.E.S. Motorsports Hang Tag LIT-11580-00-16

Y.E.S. Used Unit Registration Card LIT-11580-00-19

Y.E.S. Motorsports Brochure LIT-11580-00-36

Y.E.S. Maintenance Log LIT-11580-00-03

Y.E.S. Request to Cancel Form LIT-11580-00-10

Y.E.S. Plan Lienholder Information LIT-11580-00-08

Y.E.S. It Works DVD DVD-10660-00-04



Consumer

Side x Side Service

General Service & Warranty


Model Year Suffix Letter Chart

Model Year Suffix Letter

2004 S 2005 T 2006 V 2007 W 2008 X

2008 Side x Side Service Literature

SIDE X SIDE 12/26/07 SXS2007-010


PAGE 1 of 1



YXR70FX Rhino 700 FI 686cc 5B41 AM16Y-0000101

YXR70FHX Rhino 700 FI Hunter (Realtree® AP HD™ Camo) 686cc 5B45 AM18Y-0000101

YXR70FDUX Rhino 700 FI Ducks Unlimited® Edition 686cc 5B48 AM20Y-0000101

YXR70SPX Rhino 700 FI Sport Edition 686cc 5B4B AM21Y-0000101

YXR70FSEPX Rhino 700 FI Special Edition 1 Blue 686cc 5B49 AM23Y-0000101

YXR70FSP2X Rhino 700 FI Special Edition 2 Midnight Armor 686cc 5B4E AM24Y-0000101

YXR45FX Rhino 450 421cc 2P5A AJ32Y-0000101

YXR45FHX Rhino 450 Hunter (Realtree® AP HD™ Camo) 421cc 2P5C AJ30Y-0000101

YXR45FSPX Rhino 450 Special Edition 421cc 2P5D AJ34Y-0000101

The following is a comprehensive listing of Primary ID numbers for 2008 Yamaha Side x Sides. The frame number of a unit contains the Primary ID for warranty purposes. Production started with the listed numbers below. The Model Code appears on a label on the SxS and is useful to help identify the model when contact-ing Yamaha Parts & Accessories. This code is also referenced with other model information at the beginning of the Parts List on CD-ROM.

SIDE x SIDE 4/25/07 SXS2007-004


PAGE 1 of 2


This bulletin contains a comprehensive listing of Service Literature Part Numbers for 2007 models. Certain models will not have new literature if the prior year’s information is still current. The manu-als listed in the chart below can be ordered from Crestec Los Angeles, Inc. (Ph: 1-888-530-9446, FAX: 1-310-527-5835). This bulletin also lists other publications related to your dealership operation (see page 2), which can be ordered from Yamaha Parts and Accessories.

New ’07 Service Manual ’07 Supplement Compilation Manual Assembly Model Model Name Owner’s Manual (Main) (Supplements Only) (Main & Supplements) Manual

YXR66FW Rhino 660 LIT-11626-20-51 YXR66FAS LIT-11616-20-51 LIT-11616-RH-68* YXR66FAV LIT-11616-RH-67 LIT-11666-19-41

YXR66FSPW Rhino 660 4WD LIT-11626-20-59 YXR66FAS LIT-11616-20-51 LIT-11616-RH-68* YXR66FSPW Sport Edition LIT-11616-RH-67 LIT-11666-20-51

YXR66FSEW Rhino 660 4WD LIT-11626-20-51 YXR66FAS LIT-11616-20-51 LIT-11616-RH-68* YXR66FAV Special Edition LIT-11616-RH-67 LIT-11666-19-41

YXR66FHW Rhino 660 4WD LIT-11626-20-51 YXR66FAS LIT-11616-20-51 LIT-11616-RH-68* YXR66FAV Hardwoods™ LIT-11616-RH-67 LIT-11666-19-41 Hunter Edition Camo

YXR66FEXW Rhino 660 4WD LIT-11626-20-51 YXR66FAS LIT-11616-20-51 LIT-11616-RH-68* YXR66FAV Exploring Edition LIT-11616-RH-67 LIT-11666-19-41 Hunter Green

YXR66FDUW Rhino 660 4WD LIT-11626-20-51 YXR66FAS LIT-11616-20-51 LIT-11616-RH-68* YXR66FAV Ducks Unlimited LIT-11616-RH-67 LIT-11666-19-41 Edition

YXR45FW Rhino 450 LIT-11626-20-50 YXR45FAV LIT-11616-20-50 LIT-11616-RH-45* YXR45FAV LIT-11616-19-43 LIT-11666-19-43

YXR45FSEW Rhino 450 LIT-11626-20-50 YXR45FAV LIT-11616-20-50 LIT-11616-RH-45* YXR45FAV Special Edition LIT-11616-19-43 LIT-11666-19-43

YXR45FHW Rhino 450 Hunter LIT-11626-20-50 YXR45FAV LIT-11616-20-50 LIT-11616-RH-45* YXR45FAV LIT-11616-19-43 LIT-11666-19-43

* The manual is a compilation of the related Service Manual and Supplements. This is the part number to order for a complete manual.

PAGE 2 of 2

CATEGORY PUBLICATIONS PART NUMBER 2007 Rhino 660 Product Brochure LIT-RHINO-66-Y7 2007 Rhino Basic Orientation Video DVD-10660-00-15 2007 Rhino Accessories and Apparel Brochure LIT-ATCAT-UT-07 2005 and Earlier Side x Side Limited Warranty Statement* LIT-11790-05-03 2006 and Later Side x Side Limited Warranty Statement* LIT-11790-65-06 YXR660FA Normalized Emissions Rating Hang Tag (EPA Requirements) LIT-NER06-SS-02 YXR45FA Normalized Emissions Rating Hang Tag (EPA Requirements) LIT-NER06-SS-01 Rhino 660 Side x Side CA Emission Control Warranty LIT-19760-00-03 Side x Side Dealer Setup & Predelivery Checklist LIT-17561-00-06 2007 ATV/SxS Technical Update Book LIT-17500-AT-07 2001~2005 Technical Update DVD LIT-175MT-R5-DV 2005 SxS Service Manuals CD LIT-CDSRV-SS-05 2006 SxS Service Manuals CD LIT-CDSRV-SS-06 Heavy Duty Service Binder LIT-10501-01-80 Service Schedule Pad LIT-11561-00-96 Warranty & Y.E.S. Handbook LIT-11760-00-05 2005 SxS Flat Rate Manual LIT-17750-SS-05 Warranty Labor Rate Change Request LIT-11791-02-02 Parts System Handbook LIT-10080-07-04 Y.E.S. Plan Highlights - Motorsports LIT-11580-00-05 Y.E.S. Sample Contract LIT-11580-00-38 Y.E.S. Registration Card LIT-11580-00-04 Y.E.S. Used Hang Tag LIT-11580-00-40 Y.E.S. Motorsports Hang Tag LIT-11580-00-16 Y.E.S. Used Unit Registration Card LIT-11580-00-19 Y.E.S. Motorsports Brochure LIT-11580-00-36 Y.E.S. Maintenance Log LIT-11580-00-03 Y.E.S. Request to Cancel Form LIT-11580-00-10 Y.E.S. Plan Lienholder Information LIT-11580-00-08 Y.E.S. It Works DVD DVD-10660-00-04



Consumer

Side x Side Service



Model Year Suffix Letter Chart Model Year Suffix Letter

2004 S 2005 T 2006 V 2007 W


SIDE X SIDE 3/16/07 SXS2007-001


PAGE 1 of 1



YXR66FW Rhino 660 660cc 5UG AM04Y-0030551

YXR66FHW Rhino 660 Hunter (Hardwoods® HD Camo) 660cc 5UG AM06Y-0018201

YXR66FEXWG Rhino 660 Exploring Edition 660cc 5UG AM04Y-0030551

YXR66FDUW Rhino 660 Ducks Unlimited™ Edition 660cc 5UG AM11Y-0000101

YXR66FSEW Rhino 660 Special Edition 660cc 5UG AM08Y-0008301

YXR66SPW Rhino 660 Sport Edition 660cc 5UG AM08Y-0009001

YXR45FW Rhino 450 421cc 2P5 AJ19Y-0008201

YXR45FHW Rhino 450 Hunter (Hardwoods® HD Camo) 421cc 2P5 AJ22Y-0003101

YXR45FSEW Rhino 450 Special Edition 421cc 2P5 AJ23Y-0000101

The following is a comprehensive listing of Primary ID numbers for 2007 Yamaha Side by Sides. The frame number of a unit contains the Primary ID for warranty purposes. Production started with the listed numbers below. The Model Code appears on a label on the ATV and is useful to help identify the model when contact-ing Yamaha Parts & Accessories. This code is also referenced with other model information at the beginning of the Parts List on CD-ROM.

SIDE x SIDE 1/30/06 SXS2006-001


PAGE 1 of 2


This bulletin contains a comprehensive listing of Service Literature Part Numbers for 2006 models. Certain models will not have new literature if the prior year’s information is still current. The manu-als listed in the chart below can be ordered from Crestec Los Angeles, Inc. (Ph: 1-888-530-9446, FAX: 1-310-527-5835). This bulletin also lists other publications related to your dealership operation (see page 2), which can be ordered from Yamaha Parts and Accessories.

Owner’s Service Assembly Model Model Name Manual Manual Supplement Combos Manual

YXP700AVL Pro Hauler 700 2WD YXP700AS YXP700AS YXP700AS LIT-11626-19-39 LIT-11616-17-54 LIT-11666-17-54

YXR66FAHV Rhino 660 4WD LIT-11626-19-41 LIT-11616-RH-66 LIT-11616-19-41 LIT-11616-RH-67* LIT-11666-19-41 Hardwoods™ Hunter Edition Camo

YXR66FAEXGV Rhino 660 4WD LIT-11626-19-41 LIT-11616-RH-66 LIT-11616-19-41 LIT-11616-RH-67* LIT-11666-19-41 Exploring Edition Hunter Green YXR66FAEXHV Rhino 660 4WD LIT-11626-19-41 LIT-11616-RH-66 LIT-11616-19-41 LIT-11616-RH-67* LIT-11666-19-41 Exploring Edition Hardwoods™ Hunter Camo

YXR66FASEV Rhino 660 4WD LIT-11626-19-41 LIT-11616-RH-66 LIT-11616-19-41 LIT-11616-RH-67* LIT-11666-19-41 Special Edition

YXR66FAVGR Rhino 660 4WD LIT-11626-19-41 LIT-11616-RH-66 LIT-11616-19-41 LIT-11616-RH-67* LIT-11666-19-41 YXR45FAVGR Rhino 450 4WD LIT-11626-19-43 LIT-11616-19-43 LIT-11666-19-43

* The manual is a compilation of the related Service Manual and Supplements. This is the part number to order.

PAGE 2 of 2

CATEGORY PUBLICATIONS PART NUMBER 2006 Rhino 660 Product Brochure LIT-RHINO-66-Y6 2005 ProHauler Product Brochure LIT-HAULR-20-05 Rhino 660 Basic Orientation Video VID-10660-00-88 2006 Rhino Accessories and Apparel Brochure LIT-10080-RN-06 Side x Side Limited Warranty Statement* LIT-11790-05-03 YXR660FA Normalized Emissions Rating Hang Tag (EPA Requirements) LIT-NER06-SS-02 YXR45FA Normalized Emissions Rating Hang Tag (EPA Requirements) LIT-NER06-SS-01 Rhino 660 Side x Side CA Emission Control Warranty LIT-19760-00-03 Side x Side Dealer Setup & Predelivery Checklist LIT-17561-00-05 2005 MCY/ATV/SxS Technical Update Book LIT-17500-00-05 2001~2005 Technical Update DVD LIT-175MT-R5-DV Heavy Duty Service Binder LIT-10501-01-80 Service Schedule Pad LIT-11561-00-96 Warranty & Y.E.S. Handbook LIT-11760-00-04 2005 SxS Flat Rate Manual LIT-17750-SS-05 Warranty Labor Rate Change Request LIT-11791-02-02 Parts System Handbook LIT-10080-07-04 Y.E.S. Plan Highlights - Motorsports LIT-11580-00-05 Y.E.S. Sample Contract LIT-11580-00-38 Y.E.S. Registration Card LIT-11580-00-04 Y.E.S. Used Hang Tag LIT-11580-00-40 Y.E.S. Motorsports Hang Tag LIT-11580-00-16 Y.E.S. Used Unit Registration Card LIT-11580-00-19 Y.E.S. Motorsports Brochure LIT-11580-00-36 Y.E.S. Maintenance Log LIT-11580-00-03 Y.E.S. Request to Cancel Form LIT-11580-00-10 Y.E.S. Plan Lienholder Information LIT-11580-00-08 Y.E.S. It Works DVD DVD-10660-00-04



Consumer

Side x Side Service



Model Year Suffix Letter Chart Model Year Suffix Letter

2004 S 2005 T 2006 V


SIDE X SIDE 5/15/06 SXS2006-002

ALL 2004 ~ 2006 MODELSSide x Side Starting Primary I.D. Numbers

PAGE 1 of 1


For identification purposes of 2004 ~ 2006 models, the following lists of Starting Primary I.D. Numbers (PID) are provided below:2004

Model Model Name Starting Primary I.D. NumberYXR66FAS Rhino 660 4WD AM04Y-0000101YXR66FAHS Rhino 660 4WD Realtree Hardwoods Hunter Edition AM06Y-0000101YXP700S ProHauler 700 JW41Y-0000101YXP1000AS ProHauler 1000 JW51Y-0000101

2005

Model Model Name Starting Primary I.D. NumberYXR66FAT Rhino 660 4WD AM04Y-0008901YXR66FAHT Rhino 660 4WD Realtree Hardwoods Hunter Edition AM06Y-0003501YXP700T ProHauler 700 JW42Y-0000101YXP1000AT ProHauler 1000 JW52Y-0000101

2006

Model Model Name Starting Primary I.D. NumberYXR45FAVGR Rhino 450 4WD AJ19Y-0000101YXR66FAVGR Rhino 660 4WD AM04Y-0019201YXR66FASEV Rhino 660 4WD Special Edition AM08Y-0000101YXR66FAEXHV Rhino 660 4WD Realtree Hardwoods Exploring Edition AM06Y-0008601YXR66FAEXGV Rhino 660 4WD Exploring Edition AM04Y-0019201YXR66FAHV Rhino 660 4WD Realtree Hardwoods Hunter Edition AM06Y-0008601YXP700AVL ProHauler 700 JW42Y-0001201


SIDE X SIDE 8/20/04 SXS2004-005

2004/2005 MODELSSide x Side Paint Reference Chart


This bulletin provides paint identification and ordering information for all 2004/2005-model Side x Sides.All Side x Side paint may be ordered through Color Rite.

Color Rite Distribution Company now offers two ordering locations for your convenience. Color Rite Eastis for dealers East of the Mississippi River. Color Rite West is for dealers West of the Mississippi. Pleasenote the new addresses below:

Color Rite Distribution Company

Color Rite East Color Rite Dist. Co. (West)123 Blaine St. 1817 E. Ave. Q Ste. C-24East Bangor, PA 18013 Palmdale, CA 93550800-358-1882 - Order 800-736-7980 - Order610-588-7355 - Tech 661-266-1944 - Tech610-588-1570 - Fax 661-266-0286 - Fax

E-Mail: [email protected] Site: www.color-rite.com


When ordering, please provide Color Rite with the Year, Model, and Paint Code. Remember to providecall back information for your dealership (e.g. phone number / fax / e-mail). A Model Application Guideproviding detailed information by model year can be found at Color Rite’s web page:

www.color-rite.com


PAGE 1 of 2

“Rhino 660 Auto 4x4”YXR660FAHS/FAHT 5UG3/ Hunter Edition Body* N/A

5UG8 (Realtree Hardwoods® Frame Yamaha Black 0033 (YB) 5135High Definition Roof Support Yamaha Black 0033 (YB) 5135Camouflage) Front Bumper Chijimi Black 00W0 (WVB) 5187^

Wheel Low Gloss Black 0098 (LGB) 5654

“Rhino 660 Auto 4x4”YXR660FAS/FAT 5UG1/ Hunter Green Body* Pastel Deep Green 00K0 (PDG) 5822

5UG4 Frame Yamaha Black 0033 (YB) 5135Roof Support Yamaha Black 0033 (YB) 5135Front Bumper Chijimi Black 00W0 (WVB) 5187^Wheel Low Gloss Black 0098 (LGB) 5654

“Pro Hauler 1000 Auto”YXP1000AS/AT JW51/ Steel Blue Body* Dark Purplish Blue Solid N 0891 (DPBSN) 5290

JW52 Frame Yamaha Black 0033 (YB) 5135Front Bumper Yamaha Black 0033 (YB) 5135Wheel Low Gloss Black 0098 (LGB) 5654

“Pro Hauler 700 Auto”YXP700AS/AT JW41/ Steel Blue Body* Dark Purplish Blue Solid N 0891 (DPBSN) 5290

JW42 Frame Yamaha Black 0033 (YB) 5135Front Bumper Yamaha Black 0033 (YB) 5135Wheel Low Gloss Black 0098 (LGB) 5654

Model Yamaha Paint Code Color-RiteModel Code Sales Color Name Component Paint Color Name (Paint Code Abbr.) Paint Code

PAGE 2 of 2

2004/2005 Side x Side Paint Reference Chart

Sales Color Name isfor unit color identification and may be used for more than one paint color.

NOTE: When ordering pre-painted parts from the Parts Catalog,check the code next to the part number and this chart for color veri-fication.

Color Rite paint code information: 5000 series codes are color coats.All color coats must be clear coated.Use low gloss clear for low gloss paint.

Modelcodescan beused toconfirmthe modelyear ofthe unit.

*Paint code forreference only -Do not paint plastic body.

Rhino 660

Pro Hauler


N/A - Not Available 5187^ is nottextured.

2004/2005 Side x Side Paint Reference Chart

SIDE x SIDE 2/17/04 SXS2004-004


PAGE 1 of 2


This bulletin contains a comprehensive listing of Service Literature Part Numbers for 2004 models.Certain models will not have new literature if the prior year’s information is still current. Those literaturepart numbers will be listed, but “Same as . . .” will appear in the appropriate Manual column. The man-uals listed in the chart below can be ordered from Crestec Los Angeles, Inc. (Ph: 1-888-530-9446, FAX:1-310-527-5835). This bulletin also lists other publications related to your dealership operation (seepage 2), which can be ordered from Yamaha Parts and Accessories.


YXP1000AS ProHauler 1000 LIT-11626-17-54 LIT-11616-17-54 LIT-11666-17-54YXP700AS ProHauler 700 LIT-11626-17-54 LIT-11616-17-54 LIT-11666-17-54YXR66FAHS Rhino 660 4x4 LIT-11626-17-23 LIT-11616-17-23 LIT-11666-17-23

Hardwoods™Hunter Edition

YXR66FAS Rhino 660 4x4 LIT-11626-17-23 LIT-11616-17-23 LIT-11666-17-23

PAGE 2 of 2

CATEGORY PUBLICATIONS PART NUMBER2004 Rhino 660 Product Brochure LIT-11660-RH-Y4 2004 ProHauler Product Brochure LIT-HAULR-20-04Rhino 660 Basic Orientation Video VID-10660-00-882004 Rhino Accessories Brochure LIT-10080-RN-04Side x Side Limited Warranty Statement* LIT-11790-05-03Rhino 660 Side x Side CA Emission Control Warranty LIT-19760-00-03Side x Side Dealer Setup & Predelivery Checklist LIT-17561-00-032004 MCY/ATV/SxS Technical Update Book LIT-17500-00-04Heavy Duty Service Binder LIT-10501-01-80Service Schedule Pad LIT-11561-00-96Warranty & Y.E.S. Handbook LIT-11760-00-03Warranty Labor Rate Change Request LIT-11791-02-02Parts System Handbook LIT-10080-07-01Y.E.S. Plan Highlights - Motorsports LIT-11580-00-05Y.E.S. Sample Contract LIT-11580-00-38 Y.E.S. Registration Card LIT-11590-00-04Y.E.S. Used Hang Tag LIT-11580-00-40Y.E.S. Motorsports Hang Tag LIT-11580-00-16Y.E.S. Used Unit Registration Card LIT-11580-00-19Y.E.S. Motorsports Brochure LIT-11580-00-36Y.E.S. Maintenance Log LIT-11580-00-03Y.E.S. Request to Cancel Form LIT-11580-00-10Y.E.S. Plan Lienholder Information LIT-11580-00-08Y.E.S. It Works Video VID-10660-00-78



Consumer

Side x Side Service

General Service &Warranty

Yamaha Extended Service(Y.E.S.)



ENGINE:

Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHCBore x Stroke . . . . . . . . . . . . . . . . . . . . 84.5 x 75mm (3.33 x 2.95 in)Number Cylinders / Displacement . . . . . . . . . . . . 1 / 421cc (25.69 cu. in)Valve Clearance (Cold) - Intake . . . . . . . 0.60 ~ 0.10mm (0.0024 ~ 0.0039 in) - Exhaust . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.0063 ~ 0.0079 in)Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . Yamalube 4, 20W50Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40Oil Type - Below 0°C (32°F). . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30Capacity - Oil & Filter Change . . . . . . . . . . . . . . . . . 2.6L (2.75 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 2.5L (2.64 US qt)

CooLING SYSTEM:

Coolant Type . . Ethylene Glycol with Corrosion Inhibitors for Aluminum EnginesCoolant Ratio / Capacity . . . . . . . . . . . . . . . . . 1:1 / 2.7L (2.85 US qt)

FUEL SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single CarburetorManufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33Main Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.8 / 20Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-0M / 5ERB1Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / N/AFloat Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (0.51 in)Fuel Level . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above Gasket, SurfaceIdle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpmSet CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ~ 5%Fuel Tank Capacity - Main / Reserve . . . . . . . . . . . . . . . 30L (7.9 US gal)Fuel Type . . . . . . . . . . . . . . Unleaded Regular ( [R+M] / 2 ) 86 or Higher

TRANSMISSIoN:

Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic with ReverseOil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / øV-Belt Width / Limit . . . . . . . . . . . . . . 33.2mm (1.31 in) / 29.9mm (1.18 in)

FINAL DRIVE:

Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive Live Axle - Oil Type SAE. . . . . . . . . . . . . . . . . . 80 API GL-4 Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.25L (0.26 US qt)Front Drive Type . . . . . . Gear Drive / 2WD, 4WD Limited Slip & 4WD Locking - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API GL-4 Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.32L (0.34 US qt)

SUSPENSIoN:

Front - Toe In . . . . . . . . . . . . . . . . . . . . . 15 ~ 25mm (0.59 ~ 0.98 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TIRES:

Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . . 0.63 ~ 0.70Kg/cm (9.1 ~ 10.2 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . 0.91 ~ 0.98 Kg/cm (13.2 ~ 14.2 psi)

June 2009

YXR45FService Data

2006~“Rhino 450 4WD”

(2P5)

YXR45F 2006~ “Rhino 450 4WD” Service Data

IGNITIoN SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDISpark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR8EASpark Plug Gap . . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.024 ~ 0.028 in)Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩIgnition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩPickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561ΩRotation Sensor Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . N/ACHARGING SYSTEM:Charging System Type . . . . . . . . . . . . . . . . . . . . . . . A/C MagnetoMaximum Output . . . . . . . . . . . . . . . . . . . . . . 12V 28A @ 5000 rpmBattery - Manufacturer / Model . . . . . . . . . . ø / Wet Type, U1 Group RatingStator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.32 ~ 0.39ΩLIGHTING SYSTEM:Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5WIndicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W x 5ToRqUE VALUES:Drain Plug, Engine . . . . . . . . . . . . . . . . . . . . M14: 3.0m-kg (22 ft-lb)Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb)Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M24: 35m-kg (255 ft-lb)Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . M10: 4.8m-kg (35 ft-lb)Rear Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . . . 4.0m-kg (29 ft-lb)Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40 ft-lb)Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M24: 35m-kg (255 ft-lb)Rear Axle Nuts (See Service Manual for Procedure) . . . . . . . . . . . . . . N/ATUNE UP / MAINTENANCE PARTS:Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR8EA-00-00Oil Filter Type / Part Number . . . . . . . . . . . . Spin On / 5GH-13440-00-00Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5UG-E4451-00-00Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5UG-E4458-00-00Front / Rear Brake Lining . . . . . . . . 3LD-W0045-00-00 / 5UG-W0046-00-00Headlight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00Taillight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-000Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3FV-83517-00-00Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL)Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-14107-10-00Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5KM-17641-00-00Oil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . . 20W50 YamalubeOil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 YamalubeOil Type - Below 0°C (22°F). . . . . . . . . . . . . . . 5W40 or 5W30 YamalubeFront Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5UG-H2100-00-00Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . A5UG-26311-00-00Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 2P5-26331-00-00Park Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . .2P5-26341-00-00

ENGINE: Engine Type . . . . . . . . . . . . . . . . . . . . Liquid Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . 100 x 84mm (3.94 x 3.31 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 659cc (40.26 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . . 0.10 ~ 0.15mm (0.004 ~ 0.006 in) - Exhaust . . . . . . . . . . . . . . . . . 0.15 ~ 0.20mm (0.006 ~ 0.008 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . 2.2L (2.3 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 2.1L (2.2 US qt)

CooLING SYSTEM: Coolant Type. . . Ethylene Glycol With Corrosion Inhibitor For Aluminum Engines Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 2.5L (2.6 US qt)

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR42 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 / 40 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . O-0M / 6JPH-10 Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . N/A / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (0.51 in) Fuel Level . . . . . . . . . . . . . . . . . 3.5mm (0.14 in) Above Gask. Surface Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 - 1550 rpm Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ~ 4.5% Fuel Tank Capacity - Main / Reserve . . . . . . . . . . . . . . . 30L (7.9 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or Higher

TRANSMISSIoN: Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic with Reverse Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø V-Belt Width / Limit . . . . . . . . . . . . . . 33.2mm (1.31 in) / 29.9mm (1.18 in)

FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live” Axle - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . 0.25 L (0.26 US qt) Front Drive Type . . . . . . Gear Drive / 2WD, 4WD Limited Slip & 4WD Locking

SUSPENSIoN: Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0.0 ~ 0.39 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - Compression Damping (Std). . . . . . . . . . . . . . . . . . . . . . . N/A - Rebound Damping (Std) . . . . . . . . . . . . . . . . . . . . . . . . . N/A

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . 0.63 ~ 0.70 Kg/cm (9.1 ~ 10.2 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . 0.91 ~ 0.98 Kg/cm (13.2 ~ 14.2 psi)

June 2009

YXR66FService Data

2004~2007“Rhino 660 4WD”

(5UG)

YXR66F 2004~2007 “Rhino 660 4WD” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DPR8EA-9 Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.8 ~ 0.9mm (0.031 ~ 0.035 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . . 0.18 ~ 0.28Ω / 6.32 ~ 9.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.104 ~ 0.127Ω CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . . . . . . . . . . . “Wet” Type, U1 Group Rating System Maximum Output . . . . . . . . . . . . . . . . . . 14V 21A @ 5000 rpm Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.32 ~ 0.43Ω LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W x 5

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.0m-kg (22 ft-lb) Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5 m-kg (40 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M20: 26 m-kg (190 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . M10: 4.8 m-kg (35 ft-lb) Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5 m-kg (40 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M20: 26 m-kg (190 ft-lb) Rear Axle Nut (See Service Manual for Procedure). . . . . . . . . . . . . . N/A Rear Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . . . 4.0 m-kg (29 ft-lb)

TUNE UP / MAINTENANCE PARTS: Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DPR8E-A9-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . Spin On / 5GH-13440-00-00 Air Filter Type & Part Number . . . . . . . . . . . . . . Foam / 5UG-E4451-00-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 5UG-E4458-00-00 Front / Rear Brake Lining . . . . . . . . 3LD-W0045-00-00 / 5UG-W0046-00-00 Headlight / Taillight Bulb . . . . . . . . . . . 4KB-84314-01-00 / 1A2-84714-41-00 Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 3FV-83517-00-00 Main Fuse . . . . . . . . . . . . . . . . . . . . . . . 1AE-82151-00-00 (30A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL) Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00 Float Valve Set / . . . . . . . . . . . . . . . . . . . . . . . . 5KM-14190-30-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 5DM-14561-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5KM-17641-00-00 4-Stroke Oil . . . . . . . ACC-Y4020-40-12 (20W40), ACC-Y4010-30-12 (10W30) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4ATV-53-12 (5W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5UG-H2100-00-00 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5UG-26311-00-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 5UG-26331-00-00 Park Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5UG-26341-00-00

ENGINE: Engine Type . . . . . . . . . . . . . . . . . . . . Liquid Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 85 x 63mm (3.34 x 2.48 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 357cc (21.82 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.08 ~ 0.12mm (0.003 ~ 0.005 in) - Exhaust . . . . . . . . . . . . . . . . . 0.08 ~ 0.12mm (0.003 ~ 0.005 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . N/A - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 0.9L (1.0 US qt)

CooLING SYSTEM: Coolant Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . Mikuni / BV26-21-83 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.5 / 65 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3/8 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . N/A / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5mm (0.56 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Fuel Tank Capacity - Main / Reserve . . . . . . . . . . . . . . . 24L (6.3 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 87 or Higher

TRANSMISSIoN: Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic with Reverse Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø V-Belt Width / Limit . . . . . . . . . . . . . . 31.0mm (1.22 in) / 27.0mm (1.06 in)

FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . Gear Drive Differential Type - Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 90 Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.41L (0.44 US qt) Front Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A

SUSPENSIoN: Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 11mm (0 ~ 0.43 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . N/A - Compression Damping (Std). . . . . . . . . . . . . . . . . . . . . . . N/A - Rebound Damping (Std) . . . . . . . . . . . . . . . . . . . . . . . . . N/A

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT20 x 10-8 - Nominal Pressure. . . . . . . . . . . . . . . 0.70 ~ 0.84 Kg/cm (10.0 ~ 12.0 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT20 x 10-8 - Nominal Pressure. . . . . . . . . . . . . . . 0.70 ~ 0.84 Kg/cm (10.0 ~ 12.0 psi)

June 2009

YXP700AService Data

2004~2006“ProHauler 700”

(JW4)

YXP700A 2004~2006 “ProHauler 700” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T.C.I. Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, BPR2ES Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.7 ~ 0.8mm (0.028 ~ 0.031 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ~ 6KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in) Primary Ω / Secondary Ω . . . . . . . . . . . . . 0.72 ~ 1.80Ω / 8.40 ~ 15.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . W/R ~ W/G / 459 ~ 561Ω Rotation Sensor Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . N/A

CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . “Wet” Type, BCI Group 24 Rating, 400 CCA Min System Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . . . . . . N/A

LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2V 3.4W x 1

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M12: 2.0 m-kg (15 ft-lb) Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M14: 2.0 m-kg (15 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M12: 9.0 m-kg (65 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M14: 11.7 m-kg (85 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Rear Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M12: 9.0 m-kg (65 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . . 14.6 m-kg (106 ft-lb) Rear Axle Nut (See Service Manual for Procedure). . . . . . . . . . . . . . N/A

TUNE UP / MAINTENANCE PARTS: Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-BPR2E-S0-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Air Filter Type & Part Number . . . . . . . . . . . . . . Paper / JN6-E4450-01-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Front / Rear Brake Lining . . . . . . . . . . . . . . . . . N/A / JN6-F5331-01-00 Headlight / Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . N/A / N/A Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 123-83516-21-XX Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42X-82151-00-00 - Additional Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A - Additional Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 812-11198-00-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . JN5-14150-00-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 796-14184-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J55-G6241-00-00 4-Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . JN6-F6312-01-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . JN6-F6331-11-00 Rear Brake Cable . . . JU0-F6341-00-00 WIRE 1, JU0-F6351-00-00 WIRE 2 YXP1000

ENGINE:Engine Type . . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHCBore x Stroke . . . . . . . . . . . . . . . . . . . . 102 x 84mm (4.02 x 3.31 in)Number Cylinders / Displacement . . . . . . . . . . . . 1 / 686cc (41.86 cu. in)Valve Clearance (Cold) - Intake . . . . . . . . 0.09 ~ 0.13mm (0.004 ~ 0.005 in) - Exhaust . . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in)Premix Oil Type / Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AOil Type - Above 5°C (40°F). . . . . . . . . . . . . . . . . . Yamalube 4, 20W50Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W40Oil Type - Below 0°C (32°F). . . . . . . . . . . . . . Yamalube 4, 5W40 or 5W30Capacity - Oil & Filter Change . . . . . . . . . . . . . . . . . 2.1 L (2.2 US qt) - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 2.0 L (2.1 US qt)CooLING SYSTEM:Coolant Type . . . . .Ethylene Glycol With Corrosion Inhibitors For Aluminum EnginesCoolant Ratio / Capacity . . . . . . . . . . . . . . . . 1:1 / 2.35 L (2.48 US qt)FUEL SYSTEM:Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel InjectionManufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / 41EHSMain Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/APilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/ANeedle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AClip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . N/AFloat Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AFuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/AIdle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 ~ 1650Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ~ 10%Fuel Tank Capacity - Main / Reserve . . . . . . . . . . . 30 L (7.9 US gal) / N/AFuel Type . . . . . . . . . . . . . . . Regular Unleaded / ([R+M]/2) 86 or HigherTRANSMISSIoN:Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic With ReverseOil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINEV-Belt Width / Limit . . . . . . . . . . . . . 33.3mm (1.31 in) / 30.0mm (1.18 in))FINAL DRIVE:Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive Live Axle - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API GL-4 Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . 0.25 L (0.26 US qt)Front Drive Type . . . . . . Gear Drive / 2WD, 4WD Limited Slip & 4WD Locking - Oil Type . . . . . . . . . . . . . . . . . SAE 80 API GL-4 Hypoid Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . 0.18 L (0.19 US qt)SUSPENSIoN:Front - Toe In . . . . . . . . . . . . . . . . . . . 15.0 ~ 25.0mm (0.59 ~ 0.98 in) - Spring Preload (Std) . . . . . . . . . . . . . 2 / (SP Model: 67mm [2.64 in]) - Compression Damping (Std). . N/A / (SP Model: 10 Out From Fully Turned in Position) - Rebound Damping (Std) . . N/A / (SP Model: 10 Out From Fully Turned in Position)Rear - Spring Preload (Std) . . . . . . . . . . . . 2 (SP Model: 63.5mm [2.50 in]) - Compression Damping (Std). . .N/A / (SP Model: 7 Out From Fully Turned in Position) - Rebound Damping (Std) . . N/A / (SP Model: 12 Out From Fully Turned in Position)TIRES:Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12 - Nominal Pressure . . . . . . . . . . . . 0.63 ~ 0.70 Kg/cm (9.1 ~ 10.2 psi)Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12 - Nominal Pressure . . . . . . . . . . . . 0.91 ~ 0.98 Kg/cm (13.2 ~ 14.2 psi)

June 2009

YXR70FService Data

2008~“Rhino 700 FI”

(5B4) (42S)

YXR70F 2008~ “Rhino 700 FI” Service Data

IGNITIoN SYSTEM:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-TCISpark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . NGK, CPR7EA-9Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.8 ~ 0.9mm (0.031 ~ 0.035 in)Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩIgnition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)Primary Ω / Secondary Ω . . . . . . . . . . . . . 2.16 ~ 2.64Ω / 8.64 ~ 12.96KΩPickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . GY ~ B / 459 ~ 561ΩRotation Sensor Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . N/A

CHARGING SYSTEM:

Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . AC MagnetoBattery - Model . . . . . . . . . . . . . . . Wet Type, U1 Group Rating 340 CCASystem Maximum Output . . . . . . . . . . . . . . . . . 14V 33.5A @ 5000 rpmStator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.13 ~ 0.15ΩLIGHTING SYSTEM:

Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30WTaillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5WIndicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED

ToRqUE VALUES:

Engine Drain Plug. . . . . . . . . . . . . . . . . . . . . M14: 3.0 m-kg (22 ft-lb)Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3 m-kg (9.4 ft-lb)Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5 m-kg (40 ft-lb)Front Hub Nut (See Service Manual) . . . . . . . . . . . M20: 35 m-kg (250 ft-lb)Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . M10: 4.8 m-kg (35 ft-lb)Rear Caliper Bolts. . . . . . . . . . . . . . . . . . . . . M10: 4.8 m-kg (35 ft-lb)Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . M10: 5.5 m-kg (40 ft-lb)Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M20: 35 m-kg (250 ft-lb)


Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CPR7E-A9-00Oil Filter Type / Part Number . . . . . . . . . . . . . Spin On / 5GH-13440-20-00Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5BR-E4451-00-00Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5B4-E4472-00-00Front Brake Lining. . . . . . . . . . . . . 5B4-W0045-00-00 / 5B4-W0045-10-00Rear Brake Lining . . . . . . . . . . . . . 5B4-W0045-00-00 / 5B4-W0045-10-00Parking Brake Lining . . . . . . . . . . . . . . . . . . . . . . 5B4-W0046-00-00Headlight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00Taillight Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 5PS-82151-00-00 (40A) - Starter Relay Fuse . . . . . . . . . . . . . . . . . . 42X-82151-00-00 (10A) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-10-00 (15A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-30-00 (10A-BL) - Additional Fuse . . . . . . . . . . . . . . . . . . 5JJ-82151-50-00 (3A-BL)Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B4-17641-00-00Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . 20W50 YamalubeOil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . . 10W40 YamalubeOil Type - Below 0°C (22°F). . . . . . . . . . . . . . . 5W40 or 5W30 YamalubeFront Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTG-11U1L-D0-00Park Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 5B4-26341-00-00

ENGINE: Engine Type . . . . . . . . . . . . . . . . . . . . Liquid Cooled, 4 Stroke, SOHC Bore x Stroke . . . . . . . . . . . . . . . . . . . . . 85 x 63mm (3.34 x 2.48 in) Number Cylinders / Displacement. . . . . . . . . . . . . 1 / 357cc (21.82 cu. in) Valve Clearance (Cold) - Intake . . . . . . . . 0.08 ~ 0.12mm (0.003 ~ 0.005 in) - Exhaust . . . . . . . . . . . . . . . . . 0.08 ~ 0.12mm (0.003 ~ 0.005 in) Oil Type - Above 5°C (40°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 20W40 Oil Type - Below 15°C (60°F) . . . . . . . . . . . . . . . . . Yamalube 4, 10W30 Oil Type - Below 0°C (32°F) . . . . . . . . . . . . . . . . . . Yamalube 4, 5W30 Capacity - Oil & Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . N/A - Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 0.9L (1.0 US qt)

CooLING SYSTEM: Coolant Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A

FUEL SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . Mikuni / BV26-21-83 Main Jet / Pilot Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.5 / 65 Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3/8 Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . N/A / N/A Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5mm (0.56 in) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Fuel Tank Capacity - Main / Reserve . . . . . . . . . . . . . . . 30L (7.9 US gal) Fuel Type / Octane . . . . . . . . . . Regular Unleaded / ([R+M]/2) 87 or Higher

TRANSMISSIoN: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø V-Belt Width / Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A

FINAL DRIVE: Rear Drive Type . . . . . . . . . . . . . . . . . . . . Gear Drive Differential Type - Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 90 Gear Oil - Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.41L (0.44 US qt) Front Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A

SUSPENSIoN: Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 11mm (0 ~ 0.43 in) - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . N/ARear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . N/A - Compression Damping (Std). . . . . . . . . . . . . . . . . . . . . . . N/A - Rebound Damping (Std) . . . . . . . . . . . . . . . . . . . . . . . . . N/A

TIRES: Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 12-10 - Nominal Pressure. . . . . . . . . . . . . . . 0.70 ~ 0.84 Kg/cm (10.0 ~ 12.0 psi) Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 12-10 - Nominal Pressure. . . . . . . . . . . . . . . 0.70 ~ 0.84 Kg/cm (10.0 ~ 12.0 psi)

June 2009

YXP1000AService Data

2004~2005“ProHauler 1000”

(JW5)

YXP1000A 2004~2005 “ProHauler 1000” Service Data

IGNITIoN SYSTEM: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T.C.I. Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, BPR2ES Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.7 ~ 0.8mm (0.028 ~ 0.031 in) Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ~ 6KΩ Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Primary Ω / Secondary Ω . . . . . . . . . . . . . 0.72 ~ 1.80Ω / 8.40 ~ 15.48KΩ Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Rotation Sensor Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . N/A

CHARGING SYSTEM: Charging System Type. . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto Battery - Model . . . . . . . . . “Wet” Type, BCI Group 24 Rating, 400 CCA Min System Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . . . . . . N/A

LIGHTING SYSTEM: Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2V 3.4W x 1

ToRqUE VALUES: Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M12: 2.0 m-kg (15 ft-lb) Oil Tank Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . M14: 2.0 m-kg (15 ft-lb) Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M12: 9.0 m-kg (65 ft-lb) Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M14: 11.7 m-kg (85 ft-lb) Front Caliper Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Rear Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M12: 9.0 m-kg (65 ft-lb) Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . 14.6 m-kg (106 ft-lb) Rear Axle Nut (See Service Manual for Procedure). . . . . . . . . . . . . . N/A

TUNE UP / MAINTENANCE PARTS: Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-BPR2E-S0-00 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Air Filter Type & Part Number . . . . . . . . . . . . . . Paper / JN6-E4450-01-00 Air Filter Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Front / Rear Brake Lining . . . . . . . . . . JN6-F5331-01-00 / JN6-F5331-01-00 Headlight / Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . N/A / N/A Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 123-83516-21-XX Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42X-82151-00-00 - Additional Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A - Additional Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 812-11198-00-00 Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . JN5-14150-00-00 Float Bowl O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 796-14184-00-00 V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J55-G6241-00-00 4-Stroke Oil . . . . . . . . . . . . . . . . . . . . . ACC-Y4020-40-12 (20W40) 4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . ACC-Y4010-30-12 (10W30) Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-DR-VE Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . JN6-F6312-01-00 Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . JN6-F6331-11-00 Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . See Parts Book

Date post:	24-Apr-2018
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ATV/SxS Service Data 1995~2009 - Welcome to Maul … Manuals/YAMAHA/ATV-SxS...2008 ATV/SxS Technical...

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