Market Segment:
High-performance utility ATV (All-Terrain Vehicle) for recreational and light work applications.
Key Competitors:
Honda Foreman/Rancher, Polaris Sportsman, Can-Am Outlander, Suzuki King Quad.
Engine Power:
Powerful 686cc engine known for its torque and reliability.
Transmission:
Industry-leading Ultramatic® automatic transmission with engine braking.
Drivetrain:
On-Command® 2WD/4WD with front differential lock.
Suspension Design:
Independent front and rear suspension for superior ride comfort and handling.
Design Philosophy:
Yamaha's focus on durability, performance, and rider comfort in extreme conditions.
Engine Mechanical:
Complete engine disassembly, assembly, diagnosis, and repair for the 686cc liquid-cooled, SOHC, 4-stroke engine.
Fuel System:
Fuel injection system (EFI) components, fuel pump, injectors, throttle body, pressure regulator, and troubleshooting.
Ignition System:
CDI unit, ignition coil, spark plug, timing, and related components.
Transmission Drivetrain:
Ultramatic® automatic transmission, torque converter, drive clutch, driven clutch, belt inspection and replacement, gearbox, drive shafts, differentials (front and rear), and hub assembly.
Cooling System:
Radiator, fan, coolant hoses, water pump, thermostat, and flushing procedures.
Electrical System:
Wiring diagrams, battery, charging system (stator, rectifier/regulator), starter motor, lighting (headlights, taillights, indicators), instrumentation, and fuses.
Brakes:
Front and rear hydraulic disc brakes, brake pads, rotors, calipers, brake lines, master cylinders, and bleeding procedures.
Suspension:
Front independent suspension (double wishbone), rear independent suspension (double wishbone), shocks, springs, bushings, and alignment.
Steering:
Handlebar, steering stem, tie rods, steering knuckles, and potential inclusion of Electric Power Steering (EPS) system if applicable to specific variant covered.
Frame Chassis:
Frame inspection, welding integrity, mounting points, and overall chassis components.
Bodywork Plastics:
Fender panels, body panels, seat, and mounting hardware.
Wheels Tires:
Wheel bearing replacement, tire pressure, and basic inspection.
Preventative Maintenance:
Detailed schedules and procedures for oil changes, filter replacements, spark plug checks, air filter cleaning, coolant checks, brake fluid checks, and drive belt inspection.
Troubleshooting:
Systematic diagnostic procedures for common issues, fault code interpretation (if applicable), and step-by-step problem-solving guides.
Repair Rebuild:
Comprehensive instructions for component removal, installation, rebuilding, and adjustment for all major systems.
Specifications Settings:
Torque specifications for all fasteners, valve clearances, ignition timing, fluid capacities, and critical adjustment settings.
Wiring Diagrams:
Detailed electrical schematic diagrams with component identification and color coding.
Depth Level:
Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, electrical system diagnostics, and chassis repairs.
Diagnostic Focus:
Includes specific troubleshooting trees and diagnostic procedures for identifying root causes of performance issues, electrical faults, and mechanical failures.
Rebuild Detail:
Provides detailed instructions and specifications for rebuilding major components such as the engine, transmission, and suspension.
Engine Type:
686cc liquid-cooled, SOHC, 4-stroke, 4-valve, single-cylinder
Bore X Stroke:
100.0 mm x 83.9 mm
Fuel Induction:
Mikuni 41mm throttle body fuel injection (EFI)
Carburetor Type:
N/A (Fuel Injected)
Horsepower Rating:
Approx. 46 HP (manufacturer data may vary)
Torque Rating:
Approx. 43 lb-ft (manufacturer data may vary)
Starter System:
Electric start
Fuel Tank Capacity:
4.8 US gal (18.0 L)
Fuel Type:
Unleaded gasoline (87 octane recommended)
Engine Oil Type:
Yamalube 4 (10W-40) or equivalent API SG, SF, SG/CD SAE 10W-40
Engine Oil Capacity:
2.40 US qt (2.27 L) without oil filter change; 2.53 US qt (2.4 L) with oil filter change
Coolant Type:
Yamaha Coolant (50/50 mix of ethylene glycol) or equivalent
Transmission Type:
Ultramatic® automatic (CVT) with High, Low, Neutral, Reverse, Park
Drive System:
Yamaha On-Command® electro-hydraulic 2WD/4WD with differential lock
Final Drive:
O-ring sealed chain, Oil-bathed multi-disc clutch (in transmission)
Gear Reduction:
Front: 2.753 (36/13) / Rear: 3.571 (50/14)
Engine Braking:
Integrated engine braking through the CVT system for downhill control.
Clutch Type:
Automatic centrifugal clutch with V-belt
Transmission Oil Type:
Yamalube Performance Gear Oil 80W-90 API GL-4
Transmission Oil Capacity:
0.63 US qt (0.6 L)
Infotainment System:
N/A (Basic utility ATV; no integrated infotainment system).
Electronic Fuel Injection:
EFI provides optimized fuel delivery for improved performance, fuel economy, and cold-weather starting.
On Command 4Wd:
Electro-hydraulic engagement of 4WD and differential lock for on-the-fly adjustments to traction.
Connectivity Features:
N/A (No typical digital connectivity features like Bluetooth or USB ports).
Instrument Panel:
Digital LCD meter displaying speedometer, odometer, trip odometer, clock, fuel gauge, and 4WD indicators.
Warning Lights:
Includes warning lights for oil, battery, engine, and neutral.
Engine Oil Change Interval:
Every 2,500 km (1,550 miles) or 6 months, whichever comes first.
Air Filter Cleaning Interval:
Every 1,000 km (620 miles) or 6 months. Clean more frequently in dusty conditions.
Spark Plug Check Interval:
Check every 2,500 km (1,550 miles) or 6 months.
Transmission Oil Change Interval:
Every 5,000 km (3,100 miles) or 12 months, whichever comes first.
Coolant Flush Interval:
Every 2 years or 20,000 km (12,400 miles).
Drive Belt Inspection:
Inspect every 1,000 km (620 miles) or 6 months. Replace as needed based on wear.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Grease Type:
Lithium-based multipurpose grease.
Common Wear Items:
Drive belt, brake pads, wheel bearings, and tie rod ends due to typical ATV usage.
Potential Electrical Concerns:
While generally robust, some owners have reported issues with the CDI unit or charging system components, which this manual would help diagnose.
Cooling System Maintenance:
Regular coolant flushes and inspection of hoses are important to prevent overheating, especially under heavy load.
