Yamaha YFM45KDXK User manual

DIC2342
This ATV should not be ridden by anyone under 16 years of age.
WARNING
OWNER’S MANUAL
BB5-F8199-11LIT-11626-32-08
YFM45KDXK/YFM45KDHK
YFM45KPXK/YFM45KPLK
YFM45KPHK
READ THIS MANUAL CAREFULLY!
It contains important safety information.

EBU37021
Operating, servicing and
maintaining a passenger vehicle or off-road vehicle can
expose you to chemicals including engine exhaust,
carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and
birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the
engine except as necessary, service your vehicle in a
well-ventilated area and wear gloves or wash your
hands frequently when servicing your vehicle. For more
information go to
www.P65Warnings.ca.gov/passenger-vehicle
Read this manual carefully before operating this vehicle. This manual should stay with this ve-
hicle if it is sold.
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EBU17171
INTRODUCTION
EBU17273
Congratulations on your purchase of the Yamaha YFM45KDXK / YFM45KDHK / YFM45KPXK /
YFM45KPLK / YFM45KPHK. This ATV represents the result of many years of Yamaha experience in the
production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha,
you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader
in these fields.
This manual will provide you with a good basic understanding of the features and operation of this ATV.
This manual includes important safety information. It provides information about special techni-
ques and skills necessary to ride the ATV. It also includes basic maintenance and inspection proce-
dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a
Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
Read this manual together with TIPS FOR THE ATV RIDER carefully and completely before operating
your ATV. Make sure you understand all instructions.
Pay close attention to the warning and notice labels on the ATV.
Never operate an ATV without proper training or instruction. Free training is available to anyone who
buys a new ATV. Call 1-800-887-2887 for more information.
This ATV should not be ridden by anyone under 16 years of age.
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EBU17331
IMPORTANT MANUAL INFORMATION
EBU17344
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN-
JURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
TIP
Product and specifications are subject to change without notice.
The ATV you have purchased may differ slightly from the figures shown in this manual.
This is the safety alert symbol. It is used to alert you to potential per-
sonal injury hazards. Obey all safety messages that follow this sym-
bol to avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
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EBU17351
IMPORTANT NOTICE
EBU17363
This ATV is designed and manufactured for off-road use only. It is illegal and unsafe to operate this ATV
on any public street, road or highway.
This ATV complies with all applicable off-road noise level and spark arrester laws and regulations in effect
at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
EBU17403
YFM45KDXK / YFM45KDHK / YFM45KPXK /
YFM45KPLK / YFM45KPHK
OWNER’S MANUAL
©2019 by Yamaha Motor Corporation, U.S.A.
1st edition, February 2018
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11626-32-08
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WARNING
EWB00012
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
EBU17421
TABLE OF CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ..............................1-1
SAFETY INFORMATION ................................2-1
DESCRIPTION................................................3-1
Left view ......................................................3-1
Right view....................................................3-1
Controls and instruments............................3-2
INSTRUMENT AND CONTROL
FUNCTIONS...................................................4-1
Main switch .................................................4-1
Indicator lights and warning lights ..............4-1
Display unit ................................................. 4-4
Self-diagnosis device..................................4-5
Handlebar switches ....................................4-6
Throttle lever............................................... 4-8
Speed limiter............................................... 4-8
Front brake lever......................................... 4-9
Brake pedal and rear brake lever ............... 4-9
Drive select lever ...................................... 4-10
Fuel tank cap ............................................ 4-11
Fuel ........................................................... 4-12
Seat .......................................................... 4-13
Storage compartment............................... 4-14
Front carrier .............................................. 4-14
Rear carrier ............................................... 4-15
Front and rear shock absorbers .............. 4-15
Trailer hitch (YFM45KPXK /
YFM45KPLK / YFM45KPHK).................. 4-16
Auxiliary DC jack....................................... 4-17
Winch pre-wiring ...................................... 4-18
PRE-OPERATION CHECKS .......................... 5-1
Fuel ............................................................. 5-3
Engine oil .................................................... 5-3
Final gear oil ............................................... 5-3
Differential gear oil...................................... 5-3
Coolant ....................................................... 5-3
Front and rear brakes ................................. 5-3
Throttle lever............................................... 5-4
Tires ............................................................ 5-4
Chassis fasteners ....................................... 5-6
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Instruments, lights and switches ................ 5-6
OPERATION ...................................................6-1
Starting the engine...................................... 6-1
Operating the drive select lever and
driving in reverse....................................... 6-2
Engine break-in ........................................... 6-4
Parking ........................................................ 6-4
Parking on a slope ......................................6-5
Accessories and loading.............................6-5
RIDING YOUR ATV ........................................7-1
GETTING TO KNOW YOUR ATV ................7-2
RIDE WITH CARE AND GOOD
JUDGMENT ..............................................7-2
BE CAREFUL WHERE YOU RIDE.............7-10
TURNING YOUR ATV................................ 7-13
CLIMBING UPHILL ...................................7-15
RIDING DOWNHILL ..................................7-18
CROSSING A SLOPE................................7-19
CROSSING THROUGH SHALLOW
WATER....................................................7-20
RIDING OVER ROUGH TERRAIN ............. 7-22
SLIDING AND SKIDDING..........................7-22
WHAT TO DO IF........................................7-23
WHAT TO DO............................................7-24
PERIODIC MAINTENANCE AND
ADJUSTMENT ............................................... 8-1
Owner’s Manual and tool kit....................... 8-2
Periodic maintenance chart: Emission
control system .......................................... 8-3
Periodic maintenance chart: General
maintenance and lubrication .................... 8-5
Removing and installing panels................ 8-10
Checking the spark plug........................... 8-17
Engine oil and oil filter cartridge ............... 8-19
Final gear oil ............................................. 8-24
Changing the differential gear oil.............. 8-27
Coolant ..................................................... 8-28
Cleaning the air filter................................. 8-32
Cleaning the spark arrester ...................... 8-35
V-belt cooling duct check hose................ 8-36
V-belt case drain plug............................... 8-37
Adjusting the throttle lever free play......... 8-38
Valve clearance......................................... 8-38
Brakes....................................................... 8-38
Checking the front brake pads and rear
brake friction plates ................................ 8-39
Checking the brake fluid level .................. 8-39
Changing the brake fluid .......................... 8-41
Checking the front brake lever free play... 8-41
Adjusting the rear brake lever and brake
pedal....................................................... 8-41
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Axle boots .................................................8-46
Brake light switches .................................. 8-47
Checking and lubricating the cables......... 8-48
Checking and lubricating the front and
rear brake levers .....................................8-48
Checking and lubricating the brake
pedal .......................................................8-49
Checking the wheel hub bearings.............8-49
Lubricating the drive shaft universal
joint ......................................................... 8-50
Checking the stabilizer bushes .................8-50
Lubricating the rear knuckle pivots...........8-51
Lubricating the steering shaft ...................8-51
Battery.......................................................8-52
Replacing a fuse .......................................8-55
Replacing a headlight bulb .......................8-58
Adjusting a headlight beam ...................... 8-61
Replacing the brake/tail light bulb ............8-62
Removing a wheel.....................................8-63
Installing a wheel.......................................8-63
Troubleshooting ........................................8-65
Troubleshooting charts .............................8-66
CLEANING AND STORAGE ...........................9-1
Cleaning ......................................................9-1
Storage........................................................9-2
SPECIFICATIONS ........................................ 10-1
CONSUMER INFORMATION....................... 11-1
Identification numbers .............................. 11-1
Noise regulation........................................ 11-4
Maintenance record.................................. 11-5
YAMAHA MOTOR CORPORATION,
U.S.A. 2015 AND LATER MODEL
ATV LIMITED WARRANTY ..................... 11-6
YAMAHA EXTENDED SERVICE (Y.E.S.)... 11-8
INDEX .......................................................... 12-1
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1-1
1
EBU17661
LOCATION OF THE WARNING AND SPECIFICATION LABELS
1 2 43
8 9 10
5
7 777
6
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1-2
1
EBU17672
Read and understand all of the labels on your ATV. These labels contain important information for safe and
proper operation.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a re-
placement label from your Yamaha dealer.
: 99 lbs. (45 kg)
5ND-F4877-30
Overloading this ATV or carrying cargo improperly can change
handling, stability and braking performance and can lead to an
accident. Never exceed the maximum front cargo limit of
: 88 lbs (40 kg)
NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
Wait for the engine to return to normal idle speed
before shifting.
2UD-F151E-00
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN
CAUSE LOSS OF CONTROL.
LOSS OF CONTROL CAN RESULT IN SEVERE
INJURY OR DEATH.
OPERATING TIRE PRESSURE: Set with tires cold
• Recommended : FRONT : 5.0 psi, (35 kPa)
REAR : 4.4 psi, (30 kPa)
• Minimum : FRONT : 4.6 psi, (32 kPa)
REAR : 4.0 psi, (27 kPa)
•
Never set tire pressure belowminimum.It could cause
the tire to dislodge from the rim.
LOADING/TRAILER TOWING
• Cargo or a trailer can affect stability and handling.
Read owner’s manual before loading or towing.
•
When riding with cargo or towing a trailer : Reduce speed
and allowmore room to stop. Avoid hills and rough terrain.
• Maximum Vehicle Load : 530 lbs, (240 kg)
Includes weight of operator, cargo and accessories
(and if applicable, trailer tongue weight).
B16-F816M-U0
13
2
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1-3
1
: 187 lbs. (85 kg)
5ND-F4897-30
Overloading this ATV or carrying cargo improperly can change
handling, stability and braking performance and can lead to an
accident. Never exceed the maximum rear cargo limit of
: 176 lbs (80 kg)
NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
5880 N
1322
(600 kgf)
( 15 kgf)
37S-F151K-00
WARNING
This unit contains high pressure nitrogen gas.
Mishandling can cause explosion.
Read owner's manual for instructions.
Do not incinerate, puncture or open.
BB5-F2259-00
45
67
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1-4
1
16
UNDER
1P0-F816L-01
B4F-F817J-60
This ATVcomplies with applicable provisions of
ANSI/SVIA 1-2017 and is subject to an approved
ATVaction plan submitted by YAMAHA and on file
with the U.S. Consumer Product Safety Commission.
Certification of Compliance
YAMAHA MOTOR CORPORATIONU.S.A.
6555 Katella Avenue, Cypress, California 90630-5101, U.S.A.
WARNING
Improper ATV use can result in SEVERE
INJURY or DEATH.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate :
ALWAYS :
• without proper trainingor instruction.
• at speeds too fast for your skills or the
conditions.
• on public roads - a collision can occur
with another vehicle.
• with a passenger - passengers affect
balance and steeringand increase risk
of losingcontrol.
• use proper ridingtechniques to avoid
vehicle overturns on hills and rough
terrain and in turns.
• avoid paved surfaces - pavement may
seriously affect handlingand control.
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)
4XE-F1568-00
YAMAHA
89
10
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2-1
2
EBU17432
SAFETY INFORMATION
SAFETY INFORMATION
EBU27236
AN ATV IS NOT A TOY AND CAN BE HAZARD-
OUS TO OPERATE.
An ATV handles differently from other vehicles, in-
cluding motorcycles and cars. A collision or roll-
over can occur quickly, even during routine
maneuvers such as turning and riding on hills or
over obstacles, if you fail to take proper precau-
tions.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:
Read this manual and all labels carefully and fol-
low the operating procedures described.
Never operate an ATV without proper training or
instruction. Take a Training Course. Beginners
should receive training from a certified instruc-
tor. Contact an authorized ATV dealer or call 1-
800-887-2887 to find out about the training
courses nearest you.
Always follow the age recommendation:
– A child under 16 years old should never oper-
ate an ATV with engine size greater than 90 cc.
Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she
does not have the abilities to operate it safely.
Never carry a passenger on an ATV.
Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, park-
ing lots and streets.
Never operate an ATV on any public street, road
or highway, even a dirt or gravel one.
Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly.
You should also wear eye protection (goggles
or face shield), gloves, boots, a long-sleeved
shirt or a jacket, and long pants.
Never consume alcohol or drugs before or while
operating this ATV.
Never operate at speeds too fast for your skills
or the riding conditions. Always go at a speed
that is proper for the terrain, visibility, operating
conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
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2-2
2
Always inspect your ATV each time you use it to
make sure it is in safe operating condition. Al-
ways follow the inspection and maintenance
procedures and schedules described in this
manual.
Always keep both hands on the handlebars and
both feet on the footboards of the ATV during
operation.
Always go slowly and be extra careful when op-
erating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the
ATV.
Never operate on excessively rough, slippery or
loose terrain until you have learned and prac-
ticed the skills necessary to control the ATV on
such terrain. Always be especially cautious on
these kinds of terrain.
Always follow proper procedures for turning as
described in this manual. Practice turning at low
speeds before attempting to turn at faster
speeds and never turn at excessive speeds.
Never operate the ATV on hills too steep for the
ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
Always follow proper procedures for climbing
hills as described in this manual. Check the ter-
rain carefully before you start up any hill. Never
climb hills with excessively slippery or loose
surfaces. Shift your weight forward. Never open
the throttle suddenly. Never go over the top of a
hill at high speed.
Always follow proper procedures for going
down hills and for braking on hills as described
in this manual. Check the terrain carefully before
you start down any hill. Shift your weight back-
ward. Never go down a hill at high speed. Avoid
going down a hill at an angle that would cause
the vehicle to lean sharply to one side. Go
straight down the hill where possible.
Always follow proper procedures for crossing
the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose
surfaces. Shift your weight to the uphill side of
the ATV. Never attempt to turn the ATV around
on any hill until you have mastered the turning
technique described in this manual on level
ground. Avoid crossing the side of a steep hill if
possible.
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2-3
2
Always use proper procedures if you stall or roll
backwards when climbing a hill. To avoid stall-
ing, use the proper gear range and maintain a
steady speed when climbing a hill. If you stall or
roll backwards, follow the special procedure for
braking described in this manual. Dismount on
the uphill side or to a side if pointed straight up-
hill. Turn the ATV around and remount, following
the procedure described in this manual.
Always check for obstacles before operating in
a new area.
Never attempt to operate over large obstacles,
such as large rocks or fallen trees. Always follow
proper procedures when operating over obsta-
cles as described in this manual.
Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to
reduce the chance of skidding or sliding out of
control.
Never operate an ATV in fast flowing water or in
water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.
Always be sure there are no obstacles or people
behind you when you operate in reverse. When
it is safe to proceed in reverse, go slowly.
Always use the size and type of tires specified in
this manual.
Always maintain proper tire pressure as de-
scribed in this manual.
Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow in-
structions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for brak-
ing.
Do not operate your ATV during darkness un-
less it is equipped with a properly functioning
headlight. Off-road riding is inherently danger-
ous and additionally, off-road trails do not have
streetlights to guide you.
Never maintain an ATV without proper knowl-
edge. Contact an authorized ATV dealer to in-
form you on basic ATV maintenance. Certain
maintenance can only be carried out by certified
staff.
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2-4
2
In the event of an accident
1. If serious injuries are incurred, you may be
safer staying next to your vehicle; it may
shield you from oncoming riders. Depending
on your injuries and position in the trail; you
must make a judgment call as to whether you
should move to a position off the trail. If you
have sustained head, neck, or back injuries,
or cannot feel your limbs, you should not
move. Keep your helmet on and remain mo-
tionless. Lie down next to your vehicle and
wait for help.
2. If less serious injuries are incurred and you
can walk, then move to a position off the trail.
Check yourself for injuries and apply first aid
as needed.
3. If your injuries are light, when safe to do so,
move your vehicle off the trail to avoid colli-
sions with oncoming riders. Check for injuries
and apply first aid as necessary. If you can
physically operate your vehicle, inspect your
vehicle. If the vehicle is in safe operating con-
dition and you can safely operate it, restart it
and ride gently back to camp or other known
location where you can receive medical at-
tention. If necessary, contact your riding party
or local authorities to let them know where
you are and what has happened.
In the event of a breakdown
1. If your vehicle will not restart or is not in safe
operating condition, turn off the main switch
and engine stop switch. If the breakdown oc-
curs at twilight or night, leave the main switch
on so that your lights may warn other riders of
your stopped vehicle.
2. Get out of danger. Check for oncoming vehi-
cles and when safe, push your vehicle to the
side of the trail or even off the main trail to
avoid any possible collisions with oncoming
riders. If you cannot move your vehicle by
yourself, when safe, walk to the nearest van-
tage point and signal an oncoming rider to
help you push your vehicle to a safe place off
the trail.
3. Inspect your vehicle for any immediate haz-
ardous conditions. The most obvious hazard-
ous conditions are leaking fuel and
ungrounded or broken wiring. Visually check
for broken wiring and leaking fuel. Leaking
fuel can be confirmed by the odor of gasoline.
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2-5
2
4. Once immediate safety hazards are con-
firmed not to exist, you may remove your hel-
met to more closely inspect your vehicle.
Check for external signs of wear, broken
parts, fluid leaks, cracks in the frame, sus-
pension damage, wheel damage, and so on.
Fuel, oil, and coolant usually give off a notice-
able odor.
5. If your vehicle will not restart or if it is unsafe
to ride, then turn off all vehicle systems (en-
gine stop switch, main switch, and fuel cock),
and then signal or go for help.
Aftermarket Parts, Accessories, and Modifica-
tions
While you may find aftermarket products similar in
design and quality to genuine Yamaha accesso-
ries, recognize that some aftermarket accessories
or modifications are not suitable because of po-
tential safety hazards to you or others. Installing
aftermarket products or having other modifica-
tions performed to your vehicle that change any of
the vehicle’s design or operation characteristics
can put you and others at greater risk of serious
injury or death. You are responsible for injuries re-
lated to changes in the vehicle. Keep the following
guidelines in mind, as well as those found in the
Loading section (page 6-6) when mounting acces-
sories.
Never install accessories that would impair the
performance of your ATV. Carefully inspect the
accessory before using it to make sure that it
does not in any way reduce ground clearance,
limit suspension travel, steering travel or control
operation.
Accessories fitted to the ATV can create insta-
bility due to improper weight distribution.
Bulky or large accessories may seriously affect
the stability of the ATV.
Certain accessories can displace the operator
from his or her normal riding position. This im-
proper position limits the freedom of movement
of the operator and may limit control ability,
therefore, such accessories are not recom-
mended.
Use caution when adding electrical accesso-
ries. If electrical accessories exceed the capac-
ity of the ATV’s electrical system, an electric
failure could result, which could cause a dan-
gerous loss of lights or engine power. Also, the
battery tends to discharge more quickly if elec-
trical accessories are added.
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2-6
2
WARNING
EWB00073
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon monoxide,
a deadly gas. Breathing carbon monoxide can
cause headaches, dizziness, drowsiness, nau-
sea, confusion, and eventually death.
Carbon Monoxide is a colorless, odorless,
tasteless gas which may be present even if you
do not see or smell any engine exhaust. Deadly
levels of carbon monoxide can collect rapidly
and you can quickly be overcome and unable
to save yourself. Also, deadly levels of carbon
monoxide can linger for hours or days in en-
closed or poorly ventilated areas. If you experi-
ence any symptoms of carbon monoxide
poisoning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREATMENT.
Do not run engine indoors. Even if you try to
ventilate engine exhaust with fans or open
windows and doors, carbon monoxide can
rapidly reach dangerous levels.
Do not run engine in poorly ventilated or par-
tially enclosed areas such as barns, garages,
or carports.
Do not run engine outdoors where engine
exhaust can be drawn into a building through
openings such as windows and doors.
FOR MORE INFORMATION ABOUT ATV SAFE-
TY, call the Consumer Products Safety Commis-
sion at 1-800-638-2772, or the ATV Distributor’s
Safety Hotline at 1-800-852-5344.
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3-1
3
EBU17681
DESCRIPTION
EBU17691
Left view
EBU17701
Right view
1. Radiator cap
2. Air filter
3. Battery
4. Fuses
5. Brake/tail light
6. Engine oil filler cap
7. Oil filter cartridge
8. Coolant reservoir
9. V-belt cooling duct check hose
1 2 3 4 5
9 786
1. Spark arrester
2. Storage compartment and tool kit
3. Fuel tank cap
4. Spark plug
5. Auxiliary DC jack
6. Front shock absorber
7. Rear brake light switch
8. Brake pedal
9. V-belt case drain plug
10.Rear shock absorber
1
10 6
2 3 4 5
79 8
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3-2
3
EBU17715
Controls and instruments
1. Rear brake lever
2. Handlebar switches
3. Drive select lever
4. Display unit
5. Front brake fluid reservoir
6. On-Command drive switch “2WD/4WD”
7. Throttle lever
8. Front brake lever
9. Main switch
1 2 4 5 863 97
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