Yamaha YFM66FGX User manual

READ THIS MANUAL CAREFULLY!
It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
OWNER’S MANUAL
23D-28199-10LIT-11626-21-03
YFM66FGX
DIC2342

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INTRODUCTION
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Congratulations on your purchase of the Yamaha YFM66FGX. 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 tech-
niques 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 COMPLETE-
LY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
●PAY CLOSE ATTENTION TO THE WARNING AND CAUTION 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 INFORMA-
TION.
●THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16
YEARS OF AGE.
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IMPORTANT MANUAL INFORMATION
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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:
* Product and specifications are subject to change without notice.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury
or death to the ATV operator, a bystander, or a person inspecting or
repairing the ATV.
A CAUTION indicates special precautions that must be taken to avoid
damage to the ATV.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:
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IMPORTANT NOTICE
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Welcome to the Yamaha world of motor sports!
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.
EBU17381
AFFIX DEALER
LABEL HERE
YFM66FGX
OWNER’S MANUAL
©2007 by Yamaha Motor Corporation, U.S.A.
1st edition, March 2007
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-21-03
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WARNING
EWB00010
Indicates a potential hazard that could result
in serious injury or death.
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TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 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 light ................ 4-2
Multifunction display ................................... 4-4
Handlebar switches .................................... 4-6
Throttle lever ............................................ 4-12
Speed limiter .............................................4-13
Front brake lever .......................................4-14
Brake pedal and rear brake lever .............4-14
Drive select lever ......................................4-15
Recoil starter .............................................4-15
Fuel tank cap ............................................4-16
Fuel ...........................................................4-16
Fuel cock ..................................................4-18
Starter (choke) ..........................................4-19
Seat ..........................................................4-20
Storage compartment ...............................4-21
Front carrier ..............................................4-22
Rear carrier ...............................................4-22
Adjusting the front and
rear shock absorber assemblies .............4-22
Auxiliary DC jack .......................................4-23
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ..............................5-1
Fuel .............................................................5-4
Engine oil ....................................................5-4
Final gear oil ...............................................5-4
Differential gear oil ......................................5-4
Coolant .......................................................5-4
Front and rear brakes .................................5-5
Throttle lever ...............................................5-6
Tires ............................................................5-7
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Measuring the tire pressure ....................... 5-8
Tire wear limit ............................................. 5-9
Chassis fasteners ....................................... 5-9
Instruments, lights and switches ................ 5-9
OPERATION .................................................. 6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Operating the drive select lever and
driving in reverse ...................................... 6-3
Engine break-in .......................................... 6-5
Parking ....................................................... 6-6
Parking on a slope ..................................... 6-6
Accessories and loading ............................ 6-7
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND
GOOD JUDGEMENT................................ 7-3
BE CAREFUL WHERE YOU RIDE........... 7-13
TURNING YOUR ATV .............................. 7-19
CLIMBING UPHILL ................................... 7-21
RIDING DOWNHILL.................................. 7-25
CROSSING A SLOPE............................... 7-27
CROSSING THROUGH
SHALLOW WATER................................. 7-29
RIDING OVER ROUGH TERRAIN ........... 7-31
SLIDING AND SKIDDING .........................7-32
WHAT TO DO IF........................................7-33
WHAT TO DO............................................7-33
PERIODIC MAINTENANCE AND
MINOR REPAIR .............................................8-1
Owner’s manual and tool kit .......................8-1
Periodic maintenance chart
for the emission control system ................8-3
General maintenance and
lubrication chart ........................................8-5
Removing and installing panels ..................8-9
Checking the spark plug ...........................8-16
Engine oil and oil filter cartridge ................8-18
Final gear oil .............................................8-22
Differential gear oil ....................................8-24
Coolant .....................................................8-26
Cleaning the air filter element ...................8-31
Cleaning the spark arrester ......................8-34
V-belt cooling duct check hose .................8-36
V-belt case drain plug ...............................8-36
Adjusting the carburetor ............................8-37
Adjusting the engine idling speed .............8-37
Adjusting the throttle cable free play .........8-38
Valve clearance ........................................8-39
Adjusting the drive select lever
safety system cable ................................8-39
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Checking the front and rear brake pads ... 8-39
Checking the brake fluid level .................. 8-40
Changing the brake fluid .......................... 8-42
Checking the front brake lever
free play ................................................. 8-42
Adjusting the rear brake lever free play
and checking the brake pedal position ... 8-43
Axle boots ................................................ 8-45
Brake light switches ................................. 8-46
Checking and lubricating the cables ........ 8-46
Checking and lubricating
the front and rear brake levers ............... 8-47
Checking and
lubricating the brake pedal ..................... 8-48
Checking the wheel hub bearings ............ 8-48
Checking the stabilizer bushes ................ 8-48
Lubricating the rear knuckle pivots ........... 8-48
Lubricating the steering shaft ................... 8-49
Battery ...................................................... 8-49
Replacing a fuse ...................................... 8-51
Replacing a headlight bulb ....................... 8-52
Adjusting a headlight beam ...................... 8-54
Replacing the tail/brake light bulb ............ 8-55
Removing a wheel .................................... 8-55
Installing a wheel ...................................... 8-56
Troubleshooting ....................................... 8-57
Troubleshooting charts ............................. 8-59
CLEANING AND STORAGE ..........................9-1
Cleaning ......................................................9-1
Storage .......................................................9-2
SPECIFICATIONS .......................................10-1
CONSUMER INFORMATION.......................11-1
Identification numbers ...............................11-1
Noise regulation ........................................11-3
Maintenance record ..................................11-4
YAMAHA MOTOR CORPORATION,
U.S.A. ATV LIMITED WARRANTY .........11-5
YAMAHA EXTENDED SERVICE
(Y.E.S.) ...................................................11-7
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1-1
1
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SAFETY INFORMATION
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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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1-2
1
●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 sur-
faces. 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 backward.
Never go down a hill at high speed. Avoid going
down a hill at an angle that would cause the ve-
hicle 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 sur-
faces. 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 tech-
nique described in this manual on level ground.
Avoid crossing the side of a steep hill if possible.
●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
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