ATV/SxS Service Data 1995~2009

ATV/SxS
Service Data
1995~2009
1 PC.
LIT-SDATA-AT-00
©2009 Yamaha Motor Corporation, U.S.A.
Printed in U.S.A.
ATV
General Information
(4KD)
(1P0)
Badger
Grizzly 80
Raptor 80
Raptor 90
Breeze
Grizzly 125
Blaster
Timberwolf 2WD
Timberwolf 4WD
Bruin 250 /
Big Bear 250
BearTracker
Bruin 2WD
Bruin 4WD
YFM80
YFM80G
YFM80W
YFM90R
YFA1
YFM125G
YFS200
YFB250
YFB250F
YFM25B
YFM25X
YFM35BA
YFM35FA
YFM35FG
(4S2)
Grizzly 350
4WD IRS
Grizzly 350 2WD
Wolverine 350
Moto-4
Big Bear 4WD
Big Bear 4WD
Big Bear SE 4WD
YFM35FGI
YFM35G
YFM35X
YFM350ER
YFM350FW
YFM350FWB
YFM350FWJ
(4WU)
(5FT)
(3HN)
(3HP)
(3D5)
(5WH)
(5UH)
Grizzly 350 4WD
(5UH)
(5WH)
(4XE)
(4BD)
(5VM)
(1C5)
(3FA)
(43D)
(5TH)
(2D3)
(4EM)
(5YF)
Raptor 50
YFM50
Model
Code
Market Name
Model
1996
(H)
1995
(G)
(J)
1997
(K)
199
(L)
1999
(M)
2000
(N)
2001
(P)
2002
(R)
2003
(S)
2004
(T)
2005
(V)
2006
(W)
2007
(X)
2008
(Y)
2009
1995~2009 ATV
Data Sheet Reference
Data Sheet Reference - Page 1
(1P1)
(5GW)
(5FU)
(4S1)
(5ND)
(1D9)
(17S)
(37S)
(3C2)
Wolverine 4WD
Raptor 350
Big Bear 2WD
Warrior
Banshee
Kodiak 2WD
Kodiak 4WD
Kodiak 4WD
Big Bear 2WD
Big Bear 4WD
Big Bear 400
4WD IRS
Kodiak 2WD
Kodiak 4WD
Kodiak 4WD
Kodiak 4WD
Kodiak 4WD
Kodiak 450 4WD
Kodiak 450 4WD /
Grizzly 450 4WD
Grizzly 450 4WD
Wolverine 450
4WD
YFM350R
YFM350U
YFM350X
YFZ350
YFM4A
YFM4FA
YFM4FA
YFM40
YFM40F
YFM40FB
YFM400A
YFM400F
YFM400F
YFM400F
YFM400FA
YFM45FA
YFM45FA
YFM45FG
YFM45FX
(5GH)
(5EH)
(4SH)
(4GB)
(5HA)
(5TE))
(5VH)
(5FK)
(5NF)
(5FE)
(5YT)
(4KB)
(2D4)
YFM35FX
Model
Code
Market Name
Model
1996
(H)
1995
(G)
(J)
1997
(K)
199
(L)
1999
(M)
2000
(N)
2001
(P)
2002
(R)
2003
(S)
2004
(T)
2005
(V)
2006
(W)
2007
(X)
2008
(Y)
2009
1995~2009 ATV
Data Sheet Reference (Continued)
Data Sheet Reference - Page 2
(18P)
(28P)
(34D)
(5LP)
(5C0)
(3B4)
(43P)
YFZ450
YFZ450R
Grizzly 550 /
550 EPS
Grizzly 4WD
Grizzly 4WD
Grizzly 660 4WD
660R Raptor
Grizzly 700 /
700 EPS
Raptor 700R
YFZ450
YFZ450R
YFM5FG / P
YFM600FA
YFM600FA
YFM660F
YFM660R
YFM7FG / P
YFM70R
(1S3)
(5KM)
(2C6)
(23D)
(5GT)
(4WV)
(5TG)
(5D3)
(5TG)
YFZ450
YFZ450
Model
Code
Market Name
Model
1996
(H)
1995
(G)
(J)
1997
(K)
199
(L)
1999
(M)
2000
(N)
2001
(P)
2002
(R)
2003
(S)
2004
(T)
2005
(V)
2006
(W)
2007
(X)
2008
(Y)
2009
1995~2009 ATV
Data Sheet Reference (Continued)
Data Sheet Reference - Page 3
©2009 YAMAHA MOTOR CORPORATION, U.S.A.
All Ultramatic Models – V-Belt Information
The following information has been provided to better assist you when servicing the V-belt of an Ultramatic ATV. The following V-belt chart is also available in the new Spec Data book.
Part Number
Model
Application
Top 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.
©2008 YAMAHA MOTOR CORPORATION, U.S.A.
2008 MODELS
ATV Service Literature
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.
Model
Model
Name
Owner’s
Manual
Service Manual
’08 Supplements
New ’08
Compilation Manual
(Main)
(Supplements Only)
(Main & Supplements)
Assembly
Manual
YFM50RX
Raptor 50
LIT-11626-21-38
YFM50WS
LIT-11616-17-13
N/A
N/A
YFM50WS
LIT-11666-17-13
YFM80GX
Grizzly 80
LIT-11626-21-06
YFM80WD
LIT-11616-GZ-80
N/A
N/A
YFM80GT
LIT-11666-18-47
YFM80GHX
Grizzly 80
Hunter
LIT-11626-21-06
YFM80WD
LIT-11616-GZ-80
N/A
N/A
YFM80GT
LIT-11666-18-47
YFM80RX
Raptor 80
LIT-11626-21-23
YFM80WD
LIT-11616-YF-81
N/A
N/A
YFM80WP
LIT-11666-15-38
YFM125GX
Grizzly 125
LIT-11626-21-05
YFM125W
LIT-11616-GZ-12
N/A
N/A
YFM125S
LIT-11666-17-56
YFM125GHX
Grizzly 125
Hunter
LIT-11626-21-05
YFM125W
LIT-11616-GZ-12
N/A
N/A
YFM125S
LIT-11666-17-56
YFM25BX
Big Bear 250
LIT-11626-21-16
YFM25BT
LIT-11616-BT-26
N/A
N/A
YFM250XL
LIT-11666-12-01
YFM25RX
YFM25RSPX
YFM25RSP2X
YFM35GX
Raptor 250
Raptor 250 SE
Raptor 250 SE II
Grizzly 350 2WD
LIT-11626-21-39
LIT-11626-21-39
LIT-11626-21-39
LIT-11626-21-19
LIT-11616-21-22
LIT-11616-21-22
LIT-11616-21-22
YFM400FAR
LIT-11616-BN-20
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
LIT-11666-21-22
LIT-11666-21-22
LIT-11666-21-22
YFM35AS
LIT-11616-17-33
YFM35FGX
Grizzly 350 4WD
LIT-11626-21-17
YFM400FAR
LIT-11616-BN-35
N/A
N/A
YFM35FAS
LIT-11666-17-32
YFM35FGIX
Grizzly 350 IRS
4WD
LIT-11626-21-40
YFM35FGIW
LIT-11616-20-46
N/A
N/A
YFM35FGIW
LIT-11666-20-46
YFM35FGIHX
Grizzly 350 IRS
4WD Hunter
LIT-11626-21-40
YFM35FGIHW
LIT-11616-20-46
N/A
N/A
YFM35FGIHW
LIT-11666-20-46
YFM35FGHX
Grizzly 350 4WD
Hunter
LIT-11626-21-17
YFM400FAR
LIT-11616-BN-35
N/A
N/A
YFM35FAS
LIT-11666-17-32
YFM35RX
Raptor 350
LIT-11626-21-10
YFM350XA
LIT-11616-RP-35
N/A
N/A
YFM350S
LIT-11666-17-57
YFM35XX
Wolverine 350
2WD
LIT-11626-21-18
YFM400R
LIT-11616-FX-20
N/A
N/A
YFM35XV
LIT-11666-19-80
PAGE 1 of 3
2008 ATV Service Literature
’08 Supplements
New ’08
Compilation Manual
(Supplements Only)
(Main & Supplements)
Model
Name
Owner’s
Manual
Service Manual
YFM40FBX
Big Bear 400 4WD
LIT-11626-21-20
YFM40FBW
LIT-11616-20-45
N/A
N/A
YFM40FBW
LIT-1666-20-45
YFM40FBHX
Big Bear 400 4WD
Hunter
LIT-11626-21-20
YFM40FBHW
LIT-11616-20-45
N/A
N/A
YFM40FBHW
LIT-1666-20-45
YFM4FGX
Grizzly 400 4WD
LIT-11626-21-45
YFM400FAR
LIT-11616-KK-40
LIT-11616-21-45
LIT-11616-KK-41
YFM400FAR
LIT-11666-18-36
YFM4FGHX
Grizzly 400 4WD
Hunter
LIT-11626-21-45
YFM400FAR
LIT-11616-KK-40
LIT-11616-21-45
LIT-11616-KK-41
YFM400FAR
LIT-11666-18-36
YFM45FGX
Grizzly 450 4WD
LIT-11626-21-64
YFM450FAR
LIT-11616-KD-46
LIT-11616-21-46
LIT-11616-KD-47
LIT-11666-21-46
YFM45FGSPX
Grizzly 450 SE
LIT-11626-21-64
YFM450FAR
LIT-11616-KD-46
LIT-11616-21-46
LIT-11616-KD-47
LIT-11666-21-46
YFM45FGHX
Grizzly 450
Hunter
LIT-11626-21-64
YFM450FAR
LIT-11616-KD-46
LIT-11616-21-46
LIT-11616-KD-47
LIT-11666-21-46
YFM45FXX
Wolverine 450 4WD
LIT-11626-21-47
YFM450FAR
LIT11616-FX-45
N/A
N/A
YFM45FXV
LIT-11666-19-42
YFMFXSPX
Wolverine 450 4WD
Sport SE
LIT-11626-21-47
YFM450FAR
LIT11616-FX-45
N/A
N/A
YFM45FXV
LIT-11666-19-42
YFZ450X
YFZ450
LIT-11626-21-11
YFZ450S
LIT-11616-YF-46
N/A
N/A
YFZ450S
LIT-11666-19-32
YFZ450SPX
YFZ450 SE
LIT-11626-21-11
YFZ450S
LIT-11616-YF-46
N/A
N/A
YFZ450S
LIT-11666-19-32
YFZ450SP2X
YFZ450 SE II
(Black Flames)
LIT-11626-21-11
YFZ450S
LIT-11616-YF-46
N/A
N/A
YFZ450S
LIT-11666-19-32
YFM66FGX
Grizzly 660
LIT-11626-21-03
YFM660FP
LIT-11616-GZ-66
N/A
N/A
YFM660FP
LIT-11666-15-01
YFM66FGHX
Grizzly 660
Hunter
LIT-11626-21-03
YFM660FP
LIT-11616-GZ-66
N/A
N/A
YFM660FP
LIT-11666-15-01
YFM70RX
Raptor 700
LIT-11626-21-04
YFM70RV
LIT-11616-RP-70
N/A
N/A
YFM70RV
LIT-11666-19-13
YFM70RSPX
Raptor 700 SE
LIT-11626-21-12
YFM70RV
LIT-11616-RP-70
N/A
N/A
YFM70RV
LIT-11666-19-13
YFM70RSP2X
Raptor 700 SE II
LIT-11626-21-12
YFM70RV
LIT-11616-RP-70
N/A
N/A
YFM70RV
LIT-11666-19-13
YFM7FGX
Grizzly 700 FI 4WD
LIT-11626-21-01
YFM7FGPW
LIT-11616-20-11
LIT-11616-21-02
LIT-11616-GZ-70
YFM7FGPW
LIT-11666-20-11
YFM7FGPX
Grizzly 700 FI
EPS 4WD
LIT-11626-21-01
YFM7FGPW
LIT-11616-20-11
LIT-11616-21-02
LIT-11616-GZ-70
YFM7FGPW
LIT-11666-20-11
YFM7FGHX
Grizzly 700 FI
Hunter
LIT-11626-21-01
YFM7FGPHW
LIT-11616-20-11
LIT-11616-21-02
LIT-11616-GZ-70
YFM7FGPHW
LIT-11666-20-11
YFM7FGPHX
Grizzly 700 FI EPS
Hunter
LIT-11626-21-02
YFM7FGPHW
LIT-11616-20-11
LIT-11616-21-02
LIT-11616-GZ-70
YFM7FGPHW
LIT-11666-20-11
YFM7FGPSPX
Grizzly 700 FI SE
LIT-11626-21-02
YFM7FGPSEW
LIT-11616-20-11
LIT-11616-21-02
LIT-11616-GZ-70
YFM7FGPSEW
LIT-11666-20-11
YFM7FGPDUX
Grizzly 700 FI EPS
Ducks Unlimited
LIT-11626-21-02
YFM7FGPDUW
LIT-11616-20-11
LIT-11616-21-02
LIT-11616-GZ-70
YFM7FGPDUW
LIT-11666-20-11
Model
PAGE 2 of 3
(Main)
Assembly
Manual
2008 ATV Service Literature
OTHER PUBLICATIONS
Order the following publications from Yamaha Parts and Accessories:
CATEGORY
Consumer
General Service and Warranty
Yamaha Extended Service
(Y.E.S.)
PUBLICATIONS
PART NUMBER
2008 Utility ATV Accessory Catalog
2008 Off Road & Sport ATV Accessory Catalog
2008 ATV Full Line Mini Brochure
2008 Sport ATV Brochure
2008 Utility ATV Brochure
Tips and Practice Guide for the ATV Rider
Ride Smart, Ride Safe DVD
2006 & Later ATV Limited Warranty Statement
ATV Safety Alert
Used ATV Safety Verification Form
Y-12 Hang Tag (YFM80 models only)
Y-6 Hang Tag (YFM50 models only)
Utility Hang Tag
Sport Hang Tag
General Hang Tag (all others)
ATV Set-Up and Predelivery Checklist
2008 ATV/SxS Technical Update Book
2007 ATV Service Manual CD
Parts System Handbook
ATV Drop-off Inspection Form
Warranty Labor Rate Change Request
’95 ~ ’05 ATV Service Data Book
2008 ATV Flat Rate Manual
Warranty and Y.E.S. Handbook
Service Schedule Pad
Heavy Duty Service Binder
Y.E.S. Plan Highlights - Motorsports
Y.E.S. Motorsports Sample Contract
Y.E.S. Registration Card
Y.E.S. Used Unit Registration Card
Y.E.S. Motorsports Used Hang Tag
Y.E.S. Motorsports Hang Tag
Y.E.S. Motorsports Brochure
Y.E.S. Maintenance Log
Y.E.S. Request to Cancel Form
Y.E.S. Plan Lienholder Information
Y.E.S. It Works Video
Y.E.S. Motorsports Poster
LIT-ATCAT-UT-08
LIT-10080-YS-08
LIT-ATVMI-N1-08
LIT-11108-SP-RT
LIT-11108-UT-IL
LIT-11626-15-48
VID-17299-00-00
LIT-11790-62-06
LIT-17451-02-06
LIT-17299-01-2K
4EM-2819R-00-00
5YF-2819R-00-00
5KM-2819R-00-00
5LP-2819R-00-00
5KM-2819R-00-00
LIT-17161-00-07
LIT-17500-AT-08
LIT-CDSRV-AT-07
LIT-10080-07-04
LIT-INSPC-FM-AT
LIT-11791-02-02
LIT-SDATA-AT-00
LIT-17750-00-08
LIT-11760-00-05
LIT-11561-00-96
LIT-10501-01-80
LIT-11580-00-05
LIT-11580-00-38
LIT-11580-00-04
LIT-11580-00-19
LIT-11580-00-40
LIT-11580-00-16
LIT-11580-00-36
LIT-11580-00-03
LIT-11580-00-10
LIT-11580-00-08
DVD-10660-00-04
LIT-11580-00-41
Model Year Suffix Letter Chart
Model Year Suffix Letter Chart
Model Year
Model Year
Model Year
Model Year
1988
U
1998
K
1989
W
1999
L
1990
A
2000
M
1991
B
2001
N
1992
D
2002
P
1993
E
2003
1994
F
2004
S
1995
G
2005
T
1996
H
2006
V
1997
J
2007
W
2008
X
ROUTE TO:
! SERVICE ! PARTS !WARRANTY !SALES
R
PAGE 3 of 3
©2008 YAMAHA MOTOR CORPORATION, U.S.A.
2008 MODELS
ATV Primary ID Numbers
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
YFM50RX
Raptor 50
YFM80GX
Grizzly 80
YFM125GX
Grizzly 125
YFM80RX
YFM125GHX
5YFD
79cc
124cc
2D3A
5THL
1C5H
Starting PID No.
AA023-0000002
AB04Y-0000002
AB05Y-0000002
AE03Y-0000002
Grizzly 125 Hunter (Realtree® AP HD™ Camo)
124cc
1C5L
AE03Y-0000002
Raptor 250
249cc
4D31
AG04Y-0000032
Big Bear 250
YFM25RSPX
Raptor 250 Special Edition Black/Orange
YFM25RSP2X
Model Code
49cc
79cc
Raptor 80
YFM25BX
YFM25RX
Displacement
230cc
249cc
Raptor 250 Special Edition 2 Black
249cc
1P0D
4D35
4D39
AG05Y-0000101
AG04Y-0000032
AG04Y-0000032
YFM35RX
Raptor 350
348cc
5YTS
AH31Y-0000101
YFM35GX
Grizzly 350 2WD
348cc
5WHD
AH28Y-0002009
YFM35FGHX
Grizzly 350 4WD Hunter (Realtree® AP HD™ Camo)
348cc
5UHR
YFM35RSPX
YFM35FGX
Raptor 350 Special Edition Black
348cc
Grizzly 350 4WD
348cc
5UHL
AH30Y-0000102
AH25Y-0000101
Grizzly 350 IRS 4WD
YFM35XX
Wolverine 350 2WD
YFM40FBHX
Big Bear 400 4WD Hunter (Realtree AP HD Camo)
386cc
4S18
AH26Y-0000101
Grizzly 400 4WD Hunter (Realtree® AP HD™ Camo)
401cc
1P1G
AJ29Y-0000101
YFM40FBX
4S26
AH31Y-0000101
YFM35FGIX
YFM35FGIHX
348cc
5YT
Grizzly 350 IRS 4WD Hunter (Realtree® AP HD™ Camo)
348cc
4S2A
Big Bear 400 4WD
386cc
4S15
®
™
348cc
YFM4FGX
Grizzly 400 4WD
YFM45FGX
Grizzly 450 4WD
421cc
17S1
Grizzly 450 4WD Special Edition
421cc
17SA
YFM4FGHX
YFM45FGHX
YFM45FGSPX
Grizzly 4WD Hunter (Realtree® AP HD™ Camo)
401cc
3D56
421cc
17S5
AH29Y-0002000
AJ28Y-0014301
AJ26Y-0000101
AJ27Y-0010501
AJ36Y-0000101
Wolverine 450 4WD
YFZ450X
YFZ450
449cc
5D3B
AJ35Y-0000004
YFZ450SP2X
YFZ450 Special Edition 2 Black/Orange
449cc
5D3J
AJ35Y-0000004
YFZ450SPX
YFM66FGX
YFM66FGHX
YFM7FGX
Woverine 450 4WD Special Edition
YFZ450 Special Edition White/Blue
Grizzly 660 4WD
Grizzly 660 4WD Hunter (Realtree® AP HD™ Camo)
Grizzly 700 FI 4WD
421cc
449cc
660cc
660cc
686cc
3C2A
AH31Y-0000101
YFM45FXX
YFM45FXSPX
421cc
1P1D
AH23Y-0000101
AH24Y-0000101
3C2D
5D3E
23D1
23D5
5C01
AJ31Y-0000101
AJ33Y-0000101
AJ35Y-0000004
AM12Y-0000001
AM12Y-0000001
AM15Y-0000005
PAGE 1 of 2
2008 ATV Primary ID Numbers
Model
Model Name
Displacement
Model Code
Starting PID No.
YFM7FGHX
Grizzly 700 FI 4WD Hunter (Realtree® AP HD™ Camo)
686cc
5C05
AM15Y-0000005
YFM7FGPHX
Grizzly 700 FI 4WD EPS Hunter (Realtree® AP HD™ Camo)
686cc
3B4H
AM13Y-0000009
Grizzly 700 FI 4WD EPS Ducks Unlimited® Edition
686cc
3B4L
AM13Y-0000009
Raptor 700 Special Edition Red/White
686cc
1S3M
AM14Y-0000004
YFM7FGPX
YFM7FGPSPX
YFM7FGPDUX
Grizzly 700 FI 4WD EPS
Grizzly 700 FI 4WD EPS Special Edition
YFM70RX
Raptor 700
YFM70RSP2X
Raptor 700 Special Edition Black w/Flames
YFM70RSPX
PAGE 2 of 2
686cc
686cc
686cc
686cc
3B49
3B4M
1S3H
1S3S
AM13Y-0000009
AM13Y-0000009
AM14Y-0000004
AM14Y-0000004
©2007 YAMAHA MOTOR CORPORATION, U.S.A.
2007 MODELS
ATV Service Literature
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 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.
Model
Model
Name
Owner’s
Manual
Service Manual
’07 Supplements
New ’07
Compilation Manual
(Main)
(Supplements Only)
(Main & Supplements)
Assembly
Manual
YFM50RW
Raptor 50
LIT-11626-20-27
YFM50WS
LIT-11616-17-13
N/A
N/A
YFM50WS
LIT-11666-17-13
YFM80GW
Grizzly 80
LIT-11626-20-06
YFM80WD
LIT-11616-GZ-80
N/A
N/A
YFM80GT
LIT-11666-18-47
YFM80GHW
Grizzly 80
Hunter
LIT-11626-20-06
YFM80WD
LIT-11616-GZ-80
N/A
N/A
YFM80GT
LIT-11666-18-47
YFM80RW
Raptor 80
LIT-11626-20-14
YFM80WD
LIT-11616-YF-81
N/A
N/A
YFM80WP
LIT-11666-15-38
YFM125GW
Grizzly 125
LIT-11626-20-07
YFM125W
LIT-11616-GZ-12
N/A
N/A
YFM125S
LIT-11666-17-56
YFM125GHW
Grizzly 125
Hunter
LIT-11626-20-07
YFM125W
LIT-11616-GZ-12
N/A
N/A
YFM125S
LIT-11666-17-56
YFM25BW
Big Bear 250
LIT-11626-20-16
YFM25BT
LIT-11616-BT-26
N/A
N/A
YFM250XL
LIT-11666-12-01
YFM35GW
Grizzly 350 2WD
LIT-11626-20-19
YFM400FAR
LIT-11616-BN-20
N/A
N/A
YFM35AS
LIT-11616-17-33
YFM35FGW
Grizzly 350 4WD
LIT-11626-20-18
YFM400FAR
LIT-11616-BN-35
N/A
N/A
YFM35FAS
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
Hunter
LIT-11626-20-46
LIT-11616-20-46
N/A
N/A
LIT-11666-20-46
YFM35RW
Raptor 350
LIT-11626-20-10
YFM350XA
LIT-11616-RP-35
N/A
N/A
YFM350S
LIT-11666-17-57
YFM350RSEW Raptor 350 SE
LIT-11626-20-10
YFM350XA
LIT-11616-RP-35
N/A
N/A
YFM350S
LIT-11666-17-57
YFM350RSE2W Raptor 350
LIT-11626-20-10
YFM350XA
LIT-11616-RP-35
N/A
N/A
YFM350S
LIT-11666-17-57
LIT-11626-20-39
YFM400R
LIT-11616-FX-20
N/A
N/A
YFM35X
LIT-1666-19-80
Special Edition 2
YFM35XW
Wolverine 350
2WD Sport
PAGE 1 of 3
2007 ATV Service Literature
Model
Model
Name
Owner’s
Manual
Service Manual
(Main)
’07 Supplements
(Supplements Only)
New ’07
Compilation Manual
(Main & Supplements)
Assembly
Manual
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
Hunter
LIT-11626-20-45
LIT-11616-20-45
N/A
N/A
LIT-1666-20-45
YFM40FBEW
Big Bear 400 IRS
Exploring Edition
LIT-11626-20-45
LIT-11616-20-45
N/A
N/A
LIT-1666-20-45
YFM4FGW
Grizzly 400
LIT-11626-20-33
YFM400FAR
LIT-11616-KK-40
N/A
N/A
YFM400FAR
LIT-11666-18-36
YFM4FGHW
Grizzly 400 4WD
Hunter
LIT-11626-20-33
YFM400FAR
LIT-11616-KK-40
N/A
N/A
YFM400FAR
LIT-11666-18-36
YFM45FGW
Grizzly 450
LIT-11626-20-17
YFM450FAR
LIT-11616-KD-46
N/A
N/A
YFM450FAR
LIT-11666-16-01
YFM45FGOHW
Grizzly 450 4WD
Outdoorsman
Edition
LIT-11626-20-17
YFM450FAR
LIT-11616-KD-46
N/A
N/A
YFM450FAR
LIT-11666-16-01
YFM45FGHW
Grizzly 450
Hunter
LIT-11626-20-17
YFM450FAR
LIT-11616-KD-46
N/A
N/A
YFM450FAR
LIT-11666-16-01
YFM45FGSEW
Grizzly 450
Sport Special Edition
LIT-11626-20-17
YFM450FAR
LIT-11616-KD-46
N/A
N/A
YFM450FAR
LIT-11666-16-01
YFM45FXW
Wolverine 450 4x4
Sport
LIT-11626-20-38
YFM450FAR
LIT11616-FX-45
N/A
N/A
YFM45FXV
LIT-11666-19-42
YFMFXSEW
Wolverine 450 4x4
Sport SE
LIT-11626-20-38
YFM450FAR
LIT11616-FX-45
N/A
N/A
YFM45FXV
LIT-11666-19-42
YFZ450W
YFZ450
LIT-11626-20-13
YFZ450S
LIT-11616-YF-45
LIT-11616-20-13
LIT-11616-YF-46
YFZ450S
LIT-11666-19-32
YFZ450BBW
YFZ450
Bill Ballance Edition
LIT-11626-20-44
YFZ450S
LIT-11616-YF-45
LIT-11616-20-13
LIT-11616-YF-46
YFZ450S
LIT-11666-19-32
YFZ450SEW
YFZ450 Special Edition
LIT-11626-20-44
YFZ450S
LIT-11616-YF-45
LIT-11616-20-13
LIT-11616-YF-46
YFZ450S
LIT-11666-19-32
YFZ450SEW
YFZ450 Special Edition 2 LIT-11626-20-44
(Black Flames)
YFZ450S
LIT-11616-YF-45
LIT-11616-20-13
LIT-11616-YF-46
YFZ450S
LIT-11666-19-32
YFM66FGW
Grizzly 660
LIT-11626-20-05
YFM660FP
LIT-11616-GZ-66
N/A
N/A
YFM660FP
LIT-11666-15-01
YFM66FGHW
Grizzly 660
Hunter
LIT-11626-20-05
YFM660FP
LIT-11616-GZ-66
N/A
N/A
YFM660FP
LIT-11666-15-01
YFM70RW
Raptor 700
LIT-11626-20-12
YFM70RV
LIT-11616-19-13
LIT-11616-20-12
LIT-11616-RP-70
YFM70RV
LIT-11666-19-13
YFM700RSEW
Raptor 700
Special Edition
LIT-11626-20-34
YFM70RV
LIT-11616-19-13
LIT-11616-20-12
LIT-11616-RP-70
YFM70RV
LIT-11666-19-13
YFM70RSE2W
Raptor 700
Special Edition 2
LIT-11626-20-34
YFM70RV
LIT-11616-19-13
LIT-11616-20-12
LIT-11616-RP-70
YFM70RV
LIT-11666-19-13
YFM70RYRW
Raptor 700
GYTR Edition
LIT-11626-20-34
YFM70RV
LIT-11616-19-13
LIT-11616-20-12
LIT-11616-RP-70
YFM70RV
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
Outdoorsman Edition
LIT-11626-20-63
LIT-11616-20-11
N/A
N/A
LIT-11666-20-11
YFM7FGPHW
Grizzly 700
Hunter
LIT-11626-20-63
LIT-11616-20-11
N/A
N/A
LIT-11666-20-11
YFM45FGPSEW
Grizzly 700
Special Edition
LIT-11626-20-63
LIT-11616-20-11
N/A
N/A
LIT-11666-20-11
YFM7FGPDUW
Grizzly 700
Ducks Unlimited
Edition
LIT-11626-20-63
LIT-11616-20-11
N/A
N/A
LIT-11666-20-11
PAGE 2 of 3
2007 ATV Service Literature
OTHER PUBLICATIONS
Order the following publications from Yamaha Parts and Accessories:
CATEGORY
Consumer
General Service and Warranty
Yamaha Extended Service
(Y.E.S.)
PUBLICATIONS
PART NUMBER
2007 Utility ATV & Rhino Accessories and Apparel Catalog
2007 Sport ATV Accessories and Apparel Catalog
2007 ATV Full Line Mini Brochure
2007 Sport ATVs Brochure
2007 Utility ATVs Brochure
Tips and Practice Guide for the ATV Rider
Ride Safe, Ride Smart DVD
2006~ ATV Warranty Statement
ATV Safety Alert
Used ATV Safety Verification Form
Y-12 Hang Tag (YFM80 models only)
Y-6 Hang Tag (YFM50 models only)
Utility Hang Tag
Sport Hang Tag
General Hang Tag (all others)
ATV Set-Up and Predelivery Checklist
2001 ~ 2005 Technical Update DVD
2007 ATV/SxS Technical Update Book
’85 ~ ’94 ATV Service Manual DVD
’95 ~ ’04 ATV Service Manuals CD
2005 ATV Service Manual CD
2006-ATV Service Manual CD
Parts System Handbook
Warranty Labor Rate Change Request
’95 ~ ’05 ATV Service Data Book
2006 ATV Flat Rate Manual
Warranty and Y.E.S. Handbook
Service Schedule Pad
Heavy Duty Service Binder
Y.E.S. Plan Highlights - Motorsports
Y.E.S. Motorsports Sample Contract
Y.E.S. Registration Card
Y.E.S. Used Unit Registration Card
Y.E.S. Motorsports Used Hang Tag
Y.E.S. Motorsports Hang Tag
Y.E.S. Motorsports Brochure
Y.E.S. Maintenance Log
Y.E.S. Request to Cancel Form
Y.E.S. Plan Lienholder Information
Y.E.S. It Works Video
Y.E.S. Motorsports Poster
LIT-ATCAT-UT-07
LIT-ATCAT-SP-06
LIT-ATVMI-N1-07
LIT-11107-SP-RT
LIT-11107-UT-IL
LIT-11626-15-48
VID-17299-00-00
LIT-11790-62-06
LIT-17451-02-06
LIT-17299-01-2K
4EM-2819R-00-00
5YF-2819R-00-00
5KM-2819R-00-00
5LP-2819R-00-00
5KM-2819R-00-00
LIT-17161-00-06
LIT-175MT-R5-DV
LIT-17500-AT-07
LIT-CDSRV-AT-85
LIT-CDSRV-AT-10
LIT-CDSRV-AT-05
LIT-CDSRV-AT-06
LIT-10080-07-04
LIT-11791-02-02
LIT-SDATA-AT-00
LIT-17750-00-06
LIT-11760-00-05
LIT-11561-00-96
LIT-10501-01-80
LIT-11580-00-05
LIT-11580-00-38
LIT-11580-00-04
LIT-11580-00-19
LIT-11580-00-40
LIT-11580-00-16
LIT-11580-00-36
LIT-11580-00-03
LIT-11580-00-10
LIT-11580-00-08
DVD-10660-00-04
LIT-11580-00-41
Model Year Suffix Letter Chart
Model Year Suffix Letter Chart
Model Year
Model Year
Model Year
Model Year
1988
U
1998
K
1989
W
1999
L
1990
A
2000
M
1991
B
2001
1992
D
2002
P
1993
E
2003
R
1994
F
2004
S
1995
G
2005
T
1996
H
2006
V
1997
J
2007
W
ROUTE TO:
✓ SERVICE ✓ PARTS ✓WARRANTY ✓SALES
N
PAGE 3 of 3
©2007 YAMAHA MOTOR CORPORATION, U.S.A.
2007 MODELS
ATV Primary ID Numbers
The following is a comprehensive listing of Primary ID numbers for 2007 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
YFM50RW
Raptor 50
YFM80GW
Displacement
49cc
Model Code
5YF
Starting PID No.
AA013-0020207
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
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
YFM40FBHW
®
®
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
660cc
2C6
AM03Y-0102894
YFM66FGHW
®
Grizzly 660 4WD Hunter (Hardwoods HD Camo)
PAGE 1 of 2
2007 ATV Primary ID Numbers
Model
Model Name
YFM7FGPW
Grizzly 700 4WD
Displacement
®
Model Code
Starting PID No.
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
©2006 YAMAHA MOTOR CORPORATION, USA
2006 MODELS
ATV Service Literature
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 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.
Model
Model
Name
Owner’s
Manual
Service Manual
(Main)
Supplements
(Supplements Only)
New
Compilation Manual
(Main & Supplements)
YFM50RV
Raptor 50
LIT-11626-19-67
YFM80GV
Grizzly 80
LIT-11626-19-61
YFM80WD
LIT-11616-YF-80
LIT-11616-18-47
LIT-11616-GZ-80
YFM80GT
LIT-11666-18-47
YFM80GHV
Grizzly 80
Hunter
Hardwoods®
HD Camo
LIT-11626-19-61
YFM80WD
LIT-11616-YF-80
LIT-11616-18-47
LIT-11616-GZ-80
YFM80GT
LIT-11666-18-47
YFM80RV
Raptor 80
LIT-11626-19-64
YFM80WD
LIT-11616-YF-81
YFM80WP
LIT-11666-15-38
YFM125GV
Grizzly 125
LIT-11626-19-05
YFM125W
LIT-11616-GZ-12
YFM125S
LIT-11666-17-56
YFM125GHV
Grizzly 125
Hunter
Hardwoods®
HD Camo
LIT-11626-19-05
YFM125W
LIT-11616-GZ-12
YFM125S
LIT-11666-17-56
YFS200V
Blaster
LIT-11626-19-14
YFS200U
LIT-11616-BL-20
YFS200S
LIT-11666-17-07
YFS200SEV
Blaster SE
LIT-11626-19-15
YFS200U
LIT-11616-BL-20
YFS200S
LIT-11666-17-07
YFM25BV
Bruin 250 2WD LIT-11626-19-40
YFM25BT
LIT-11616-BT-26
YFM250XL
LIT-11666-12-01
YFM35BAV
Bruin 350 2WD LIT-11626-19-66
YFM400FAR
LIT-11616-BN-20
YFM35AS
LIT-11616-17-33
YFM35FAV
Bruin 350 4WD LIT-11626-19-65
YFM400FAR
LIT-11616-BN-35
YFM35FAS
LIT-11666-17-32
YFM35FAHV
Bruin 350 4WD LIT-11626-19-65
Hunter
Hardwoods®
HD Camo
YFM400FAR
LIT-11616-BN-35
YFM35FAHS
LIT-11666-17-32
YFM35XV
Wolverine 350
2WD
YFM400FAR
LIT-11616-BN-20
LIT-11626-19-80
YFM50WS
LIT-11616-17-13
Assembly
Manual
YFM50WS
LIT-11666-17-13
LIT-11616-19-80
LIT-11616-FX-20
LIT-1666-19-80
PAGE 1 of 4
2006 ATV Service Literature
Supplements
New
Compilation Manual
Model
YFM350RV
Model
Name
Raptor 350
Owner’s
Service Manual
(Main)
Manual
LIT-11626-19-68
YFM350XA
LIT-11616-RP-35
YFM350RSEV
Raptor 350 SE
LIT-11626-19-68
YFM350XA
LIT-11616-RP-35
YFM350S
LIT-11666-17-57
YFZ350V
Banshee
LIT-11626-19-15
YFZ350T
LIT-11616-YF-37
YFZ350S
LIT-11666- 17-04
YFZ350SEV
Banshee SE
LIT-11626-19-15
YFZ350T
LIT-11616-YF-37
YFZ350LES
LIT-11666- 17-04
YFZ350SPV
Banshee SP
50th Anniv. Ed.
LIT-11626-19-15
YFZ350T
LIT-11616-YF-37
YFZ350LES
LIT-11666- 17-04
YFM40FV
Big Bear 400 4WD LIT-11626-19-62
YFM400FM
LIT-11616-BB-40
YFM40FWNM
LIT-11666-13-22
YFM4FAV
Kodiak 400 4WD
LIT-11626-19-58
YFM4FAHV
Kodiak 400 4WD
Hunter
Hardwoods® HD
Camo
LIT-11626-19-58
YFM400FAR
LIT-11616-KK-40
YFM400FAR
LIT-11616-KK-40
YFM400FAR
LIT-11666-18-36
YFM400FAR
LIT-11666-18-36
YFM45FAV
Kodiak 450 4WD
LIT-11626-19-57
YFM450FAR
LIT-11616-KD-46
YFM450FAR
LIT-11666-16-01
YFM45FABGGV Kodiak 450
Outdoorsman
Edition Hunter
Green
LIT-11626-19-57
YFM450FAR
LIT-11616-KD-46
YFM450FAR
LIT-11666-16-01
YFM45FABGHV Kodiak 450
Outdoorsman
Edition Hunter
Hardwoods® HD
Camo
LIT-11626-19-57
YFM450FAR
LIT-11616-KD-46
YFM450FAR
LIT-11666-16-01
YFM45FAHV
Kodiak 450 4WD
Hunter
Hardwoods® HD
Camo
LIT-11626-19-57
YFM450FAR
LIT-11616-KD-46
YFM450FAR
LIT-11666-16-01
YFM45FASEV
Kodiak 450 4WD
SE
LIT-11626-19-57
YFM450FAR
LIT-11616-KD-46
YFM450FAR
LIT-11666-16-01
(Supplements Only)
(Main & Supplements)
Assembly
Manual
YFM350S
LIT-11666-17-57
YFM45FXV
Wolverine 450 4WD LIT-11626-19-42 LIT-11616-16-01
LIT-11616-FX-45
LIT-11666-19-42
YFZ450V
YFZ450
YFZ450S
LIT-11616-17-11
LIT-11616-19-32
LIT-11616-YF-45
LIT-11666-19-32
YFZ450BBV
YFZ450
LIT-11626-19-63
YFZ450S
Bill Ballance Edition
LIT-11616-17-11
LIT-11616-19-32
LIT-11616-YF-45
LIT-11666-19-32
YFZ450SPV
YFZ450 SP
50th Anniv. Edition
LIT-11626-19-77
YFZ450S
LIT-11616-17-11
LIT-11616-19-32
LIT-11616-YF-45
LIT-11666-19-32
YFM66FAV
Grizzly 660
LIT-11626-19-60
YFM660FP
LIT-11616-GZ-66
YFM660FP
LIT-11666-15-01
YFM66FAHV
Grizzly 660
Hunter
Hardwoods® HD
Camo
LIT-11626-19-60
YFM660FP
LIT-11616-GZ-66
YFM660FP
LIT-11666-15-01
LIT-11626-19-60
YFM660FP
LIT-11616-GZ-66
YFM660FP
LIT-11666-15-01
YFM66FABGGV Grizzly 660 4WD
Outdoorsman Ed.
Hunter Green
PAGE 2 of 4
LIT-11626-19-77
LIT-11616-19-42
2006 ATV Service Literature
Model
Model
Name
Owner’s
Manual
Service Manual
(Main)
Supplements
(Supplements Only)
New
Compilation Manual
(Main & Supplements)
Assembly
Manual
YFM66FABGHV
Grizzly 660 4WD LIT-11626-19-60
YFM660FP
Outdoorsman Ed.
LIT-11616-GZ-66
Hunter
Hardwoods HD
Camo
YFM660FP
LIT-11666-15-01
YFM66FASEV
Grizzly 660 SE
YFM660FP
LIT-11616-GZ-66
YFM660FP
LIT-11666-15-01
YFM66FAHDV
Grizzly 660
LIT-11626-19-60
YFM660FP
Ducks Unlimited®
LIT-11616-GZ-66
YFM660FP
LIT-11666-15-01
YFM700RV
Raptor 700
YFM700RSPV
Raptor 700 SP
50th Anniv. Ed.
LIT-11626-19-60
LIT-11626-19-59 LIT-11616-19-13
LIT-11666-19-13
LIT-11626-19-59 LIT-11616-19-13
LIT-11666-19-13
OTHER PUBLICATIONS
Order the following publications from Yamaha Parts and Accessories:
CATEGORY
Consumer
General Service and Warranty
Yamaha Extended Service
(Y.E.S.)
PUBLICATIONS
PART NUMBER
2006 ATV Utility Accessory Brochure
2006 Sport ATV Accessory Brochurre
2006 ATV Full Line Mini Brochure
2006 Sports ATVs Brochure
2006 Utility ATVs Brochure
Tips and Practice Guide for the ATV Rider
Ride Safe, Ride Smart Videotape
ATV Rally CD-ROM
2006~ ATV Warranty Statement*
ATV Safety Alert
Used ATV Safety Verification Form
Y-12 Hang Tag (YFM80 models only)
Y-6 Hang Tag (YFM50 models only)
Utility Hang Tag
Sport Hang Tag (660R Raptor, Banshee, Warrior, Blaster)
General Hang Tag (all others)
ATV Set-Up and Predelivery Checklist
2006 MCY/ATV/SxS Technical Update Book
’95 ~ ’04 ATV Service Manuals CD
2005 ATV Service Manual CD
2006-ATV Service Manual CD
Parts System Handbook
Warranty Labor Rate Change Request
’95 ~ ’05 ATV Service Data Book
2005 ATV Flat Rate Manual
Warranty and Y.E.S. Handbook
Service Schedule Pad
Heavy Duty Service Binder
Y.E.S. Plan Highlights - Motorsports
Y.E.S. Motorsports Sample Contract
Y.E.S. Registration Card
Y.E.S. Used Unit Registration Card
Y.E.S. Motorsports Used Hang Tag
Y.E.S. Motorsports Hang Tag
Y.E.S. Motorsports Brochure
Y.E.S. Maintenance Log
Y.E.S. Request to Cancel Form
Y.E.S. Plan Lienholder Information
Y.E.S. It Works Video
Y.E.S. Motorsports Poster
LIT-ATCAT-UT-06
LIT-ATCAT-SP-06
LIT-ATVMI-N1-06
LIT-11106-SP-RT
LIT-11106-UT-IL
LIT-11626-15-48
VID-17299-00-00
LIT-17299-CD-00
LIT-11790-62-06
LIT-17451-02-05
LIT-17299-01-2K
4EM-2819R-00-00
5YF-2819R-00-00
5KM-2819R-00-00
5LP-2819R-00-00
5KM-2819R-00-00
LIT-17161-00-05
LIT-17500-00-06
LIT-CDSRV-AT-10
LIT-CDSRV-AT-05
LIT-CDSRV-AT-06
LIT-10080-07-04
LIT-11791-02-02
LIT-SDATA-AT-00
LIT-17750-00-05
LIT-11760-00-04
LIT-11561-00-96
LIT-10501-01-80
LIT-11580-00-05
LIT-11580-00-38
LIT-11580-00-04
LIT-11580-00-19
LIT-11580-00-40
LIT-11580-00-16
LIT-11580-00-36
LIT-11580-00-03
LIT-11580-00-10
LIT-11580-00-08
DVD-10660-00-04
LIT-11580-00-41
PAGE 3 of 4
2006 ATV Service Literature
Model Year Suffix Letter Chart
Model Year
Model Year
PAGE 4 of 4
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
ROUTE TO:
✓ SERVICE ✓ PARTS ✓WARRANTY ✓SALES
©2006 YAMAHA MOTOR CORPORATION, USA
2006 MODELS
ATV Primary ID Numbers
The following is a comprehensive listing of Primary ID numbers for 2006 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
YFM50RV
Raptor 50
Displacement
49cc
Model Code
5YF
AA013-0014769
Starting PID No.
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
Hunter Green
421cc
1D9
AJ16Y-0005301
YFM45FASEV
Kodiak 450 4WD Special Edition
421cc
1D9
AJ18Y-0000101
YFM45FABGHV
Kodiak 450 Outdoorsman Edition w/Kit
(Hardwoods® HD Camo)
421cc
1D9
AJ16Y-0005301
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
PAGE 1 of 2
2006 ATV Primary ID Numbers
Model
Model Name
YFM66FAV
Grizzly 660 4WD
Displacement
660cc
Model Code
2C6
Starting PID No.
AM03Y-0082365
YFM66FABGGV
Grizzly 660 4WD Outdoorsman Edition w/Kit
Hunter Green
660cc
2C6
AM03Y-0082365
YFM66FABGHV
Grizzly 660 4WD Outdoorsman Edition w/Kit
(Hardwoods® HD Camo)
660cc
2C6
AM03Y-0082365
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
©2005 YAMAHA MOTOR CORPORATION, USA
2005 MODELS
ATV Paint Reference Chart
This bulletin provides paint identification and ordering information for all 2005-model ATVs. All ATV paint
may be ordered through Color Rite:
Color Rite Distribution Company offers two ordering locations for your convenience. Color Rite East is
for 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 Company
Color Rite East
Color Rite Dist. Co. (West)
123 Blaine St.
1817 E. Ave. Q, Ste. C-24
East Bangor, PA 18013
Palmdale, CA 93550
800-358-1882 - Order
800-736-7980 - Order
610-588-7355 - Tech
661-266-1944 - Tech
610-588-1570 - Fax
661-266-0286 - Fax
E-Mail: colorritewtr@earthlink.net
Web Site: www.color-rite.com.
As an added benefit, orders received by 2:00 pm (Eastern Standard Time for Color Rite East and Pacific
Standard 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 number / fax / e-mail). A Model Application Guide providing detailed information by model year can be found
at Color Rite’s web page:
www.color-rite.com
For previous model year paint information, please refer to the following:
•
•
•
•
•
•
•
(’91~’99)
(’91~’99)
(’99~’00)
(2001)
(2002)
(2003)
(2004)
Paint Reference Guide (P/N: LIT-10030-PC-99)
Summer ’99 Paint Chart Reference Guide (P/N: LIT-10030-PC-2K)
ATV Paint Reference Chart (Technical Bulletin AT2001-005)
ATV Paint Reference Chart (Technical Bulletin AT2001-003)
ATV Paint Reference Chart (Technical Bulletin AT2001-009)
ATV Paint Reference Chart (Technical Bulletin AT2003-002)
ATV Paint Reference Chart (Technical Bulletin AT2004-004)
NOTE: The following paint chart is also very useful when ordering pre-painted and plastic body parts
from the parts catalog. Paint codes are generally listed next to the part number of the pre-painted or
plastic body part. This chart can be used to confirm the color of the part you are ordering. The Sales
color name may be used for more than one paint color.
PAGE 1 of 6
2005 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
UTILITY
“Grizzly 660 Auto 4x4”
(Hardwoods® Camo
Hunter Edition
YFM66FAHT
2C61
Hunter Edition
(Realtree Hardwoods®
Camouflage)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Low Gloss Black
Chijimi Black
Low Gloss Black
0033
0098
00W0
0098
(YB)
(LGB)
(WVB)
(LGB)
5135
5654
5187^
5654
“Grizzly 660 Auto 4x4”
(Wetlands™ Camo
Hunter Edition)
YFM66FAHWT
2C62
Hunter Edition
Body*
(Advantage® Wetlands™ Frame
Camouflage)
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Low Gloss Black
Chijimi Black
Low Gloss Black
0033
0098
00W0
0098
(YB)
(LGB)
(WVB)
(LGB)
5135
5654
5187^
5654
“Grizzly 660 Auto 4x4”
YFM660FASET
2C63
Metallic Black
(Special Edition)
Body
Frame
Front Bumper
Carrier (F&R)
Wheel
Black Metallic L
Yamaha Black
Silver 8
Chijimi Black
No paint
0965
0033
0095
00W0
(SML)
(YB)
(S8)
(WVB)
TBA
5135
5265
5187^
“Grizzly 660 Auto 4x4”
YFM66FAT
5KMU
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Chijimi Black
No paint
00K0
0033
00MA
00W0
(PDG)
(YB)
(TGM)
(WVB)
5822
5135
5860
5187^
Steel Blue (L)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Titanic Gray Metallic
Chijimi Black
No paint
0891
0033
00MA
00W0
(DPBSN)
(YB)
(TGM)
(WVB)
5290
5135
5860
5187^
Red (R)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Chijimi Black
No paint
00TR
0033
00MA
00W0
(RTR)
(YB)
(TGM)
(WVB)
5650
5135
5860
5187^
“Kodiak 450 Auto 4X4”
(Hardwoods® Camo
Hunter Edition)
YFM45FAHT
1D95
Hunter Edition
(Realtree Hardwoods®
Camouflage)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0033
00W0
00W0
0098
(YB)
(WVB)
(WVB)
(LGB)
5135
5187^
5187^
5654
“Kodiak 450 Auto 4X4”
YFM45FASET
1D98
Metallic Black
(Special Edition)
Body
Frame
Front Bumper
Carrier (F&R)
Wheel
Black Metallic L
Low Gloss Black
Silver 8
Chijimi Black
Low Gloss Black
0965
0098
0895
00W0
0098
(SML)
(LGB)
(S8)
(WVB)
((LGB)
TBA
5654
5265
5187*
5654
“Kodiak 450 Auto 4X4”
YFM45FAT
1D91
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00K0
0033
00W0
00W0
00MA
(PDG)
(YB)
(WVB)
(WVB)
(TGM)
5822
5135
5187^
5187^
5860
Steel Blue (L)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
0891
0033
00W0
00W0
00MA
(DPBSN)
(YB)
(WVB)
(WVB)
(TGM)
5290
5135
5187^
5187^
5860
Red (R)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00TR
0033
00W0
00W0
00MA
(RTR)
(YB)
(WVB)
(WVB)
(TGM)
5650
5135
5187^
5187^
5860
*Paint code for reference only - Do
not paint plastic
body.
N/A - Not Available.
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the parts list,
the code next to the part
number, and this chart for
color verification.
PAGE 2 of 6
Model
codes can
be used to
confirm the
model year
of the unit.
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
^5187 is not
textured.
TBA – To Be
Announced
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.
2005 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
UTILITY (CONT’D)
“Kodiak 400 Auto 4x4”
(Hardwoods® Camo
Hunter Edition)
YFM4FAHT
1P14
Hunter Edition
(Realtree Hardwoods®
Camouflage)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0033
00W0
00W0
0098
(YB)
(WVB)
(WVB)
(LGB)
5135
5187^
5187^
5654
“Kodiak 400 Auto 4X4”
YFM4FAT
1P11
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00K0
0033
00W0
00W0
0098
(PDG)
(YB)
(WVB)
(WVB)
(LGB)
5822
5135
5187^
5187^
5654
Steel Blue (L)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0891
0033
00W0
00W0
0098
(DPBSN)
(YB)
(WVB)
(WVB)
(LGB)
5290
5135
5187^
5187^
5654
Red (R)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00TR
0033
00W0
00W0
0098
(RTR)
(YB)
(WVB)
(WVB)
(LGB)
5650
5135
5187^
5187^
5654
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00K0
0033
00W0
00W0
0098
(PDG)
(YB)
(WVB)
(WVB)
(LGB)
5822
5135
5187^
5187^
5654
Steel Blue (L)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0891
0033
00W0
00W0
0098
(DPBSN)
(YB)
(WVB)
(WVB)
(LGB)
5290
5135
5187^
5187^
5654
Red (R)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00TR
0033
00W0
00W0
0098
(RTR)
(YB)
(WVB)
(WVB)
(LGB)
5650
5135
5187^
5187^
5654
“Big Bear 400 4X4”
YFM40FT
“Wolverine”
YFM35FXT
“Bruin 350 Auto 4x4”
(Hardwoods® Camo
Hunter Edition)
YFM35FAHT
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
5FUF
2D41
5UHA
Model
codes can
be used to
confirm the
model year
of the unit.
Black (B)
Body*
Frame
Front Bumper
Carrier (R)
Wheel
Yamaha Black
Yamaha Black
Silver 8
Yamaha Black
Silver
0033
0033
0895
0033
0035
(YB)
(YB)
(S8)
(YB)
(SL)
5135
5135
5265
5135
5616
White/Red (W)
Body*
Frame
Front Bumper
Carrier (R)
Wheel
Bluish White Solid 1
Yamaha Black
Vivid Red Cocktail 7
Yamaha Black
Silver
0892
0033
0580
0033
0035
(BWS1)
(YB)
(VRC7)
(YB)
(SL)
5780
5135
1300-1 + 5826
5135
5616
Hunter Edition
(Realtree Hardwoods®
Camouflage)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0033
00W0
00W0
0098
(YB)
(WVB)
(WVB)
(LGB)
5135
5187^
5187^
5654
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
*Paint code for reference only - Do
not paint plastic
body.
N/A – Not
Applicable
^5187 is not
textured.
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 3 of 6
2005
ATV
Paint
Reference
Chart
2005
ATV
Paint
Reference
Chart
MODEL
MODEL
MODEL
MODEL
CODE
CODE
SALES
SALES
COLOR
NAME
COLOR
NAME
COMPONENT
COMPONENT
PAINT
PAINT
COLOR
NAME
COLOR
NAME
YAMAHA
RITE
YAMAHA COLOR
COLOR
RITE
PAINT
CODE
CODE
PAINT
CODE PAINT
PAINT
CODE
UTILITY
(CONT’D)
UTILITY
(CONT’D)
“Bruin
350 350
Auto
4x4”4x4”
“Bruin
Auto
YFM35FAT
YFM35FAT
“Bruin
350 350
Automatic”
“Bruin
Automatic”
YFM35BAT
YFM35BAT
“Bruin
250”250”
“Bruin
YFM250BT
YFM250BT
5UH6
5UH6
Hunter
Green
(GR)(GR)
Hunter
Green
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Pastel
Deep
Green
Pastel
Deep
Green
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
00K0
00K0(PDG)
(PDG)
00330033(YB)(YB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00980098(LGB)
(LGB)
Steel
BlueBlue
(L) (L)
Steel
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
DarkDark
Purplish
BlueBlue
SolidSolid
N N
Purplish
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
08910891(DPBSN)
52905290
(DPBSN)
00330033(YB)(YB) 51355135
00W0
(WVB)
00W0
(WVB) 5187^
5187^
00W0
(WVB)
00W0
(WVB) 5187^
5187^
00980098(LGB)
(LGB) 56545654
RedRed
(R) (R)
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Romantique
Rouge
Romantique
Rouge
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
00TR
(RTR)
00TR
(RTR)
00330033(YB)(YB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00980098(LGB)
(LGB)
56505650
51355135
5187^
5187^
5187^
5187^
56545654
5WH4
Green
(GR)(GR)
5WH4 Hunter
Hunter
Green
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Pastel
Deep
Green
Pastel
Deep
Green
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
00K0
00K0(PDG)
(PDG)
00330033(YB)(YB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00980098(LGB)
(LGB)
58225822
51355135
5187^
5187^
5187^
5187^
56545654
Steel
BlueBlue
(L) (L)
Steel
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
DarkDark
Purplish
BlueBlue
SolidSolid
N N
Purplish
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
08910891(DPBSN)
52905290
(DPBSN)
00330033(YB)(YB) 51355135
00W0
(WVB)
00W0
(WVB) 5187^
5187^
00W0
(WVB)
00W0
(WVB) 5187^
5187^
00980098(LGB)
(LGB) 56545654
RedRed
(R) (R)
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Romantique
Rouge
Romantique
Rouge
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
00TR
(RTR)
00TR
(RTR)
00330033(YB)(YB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00980098(LGB)
(LGB)
56505650
51355135
5187^
5187^
5187^
5187^
56545654
Hunter
Green
(GR)(GR)
Hunter
Green
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Pastel
Deep
Green
Pastel
Deep
Green
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
00K0
00K0(PDG)
(PDG)
00330033(YB)(YB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00980098(LGB)
(LGB)
58225822
51355135
5187^
5187^
5187^
5187^
56545654
Steel
BlueBlue
(L) (L)
Steel
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
DarkDark
Purplish
BlueBlue
SolidSolid
N N
Purplish
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
08910891(DPBSN)
52905290
(DPBSN)
00330033(YB)(YB) 51355135
00W0
(WVB)
00W0
(WVB) 5187^
5187^
00W0
(WVB)
00W0
(WVB) 5187^
5187^
00980098(LGB)
(LGB) 56545654
RedRed
(R) (R)
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Romantique
Rouge
Romantique
Rouge
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
00TR
(RTR)
00TR
(RTR)
00330033(YB)(YB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00980098(LGB)
(LGB)
1P01
1P01
58225822
51355135
5187^
5187^
5187^
5187^
56545654
56505650
51355135
5187^
5187^
5187^
5187^
56545654
“Grizzly
125”125”
“Grizzly
®
®
Camo
(Hardwoods
Camo
(Hardwoods
Hunter
Edition)
Hunter
Edition)
YFM125GHT
YFM125GHT
1C58
1C58
Hunter
Edition
Body*
Hunter
Edition
Body*
®
® Frame
(Realtree
Hardwoods
(Realtree
Hardwoods
Frame
Camouflage)
Front
Bumper
Camouflage)
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
N/A N/A
Yamaha
Black
Yamaha
Black
Mat Mat
Black
2 2
Black
Mat Mat
Black
2 2
Black
LowLow
Gloss
Black
Gloss
Black
00330033(YB)(YB) 51355135
05820582(MBL2)
(MBL2) 59885988
05820582(MBL2)
(MBL2) 59885988
00980098(LGB)
(LGB) 56545654
“Grizzly
125”125”
“Grizzly
YFM125GT
YFM125GT
1C55
1C55
Hunter
Green
(GR)(GR)
Hunter
Green
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Pastel
Deep
Green
Pastel
Deep
Green
Yamaha
Black
Yamaha
Black
Mat Mat
Black
2 2
Black
Mat Mat
Black
2 2
Black
Silver
Silver
00K0
00K0(PDG)
(PDG) 58225822
00330033(YB)(YB) 51355135
05820582(MBL2)
(MBL2) 59885988
05820582(MBL2)
(MBL2) 59885988
00350035(SL)(SL)
56165616
Steel
BlueBlue
(L) (L)
Steel
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
DarkDark
Puplish
BlueBlue
SolidSolid
N N
Puplish
Yamaha
Black
Yamaha
Black
Mat Mat
Black
2 2
Black
Mat Mat
Black
2 2
Black
Silver
Silver
08910891(DPBSN)
52905290
(DPBSN)
00330033(YB)(YB) 51355135
05820582(MBL2)
(MBL2) 59885988
05820582\(MBL2)
\(MBL2)59885988
00350035(SL)(SL)
56165616
NOTE:
When
ordering
The The
Sales
Color
NOTE:
When
ordering
Sales
Color
Model
Model
pre-painted
or plastic
bodybody codes
is forisunit
pre-painted
or plastic
Name
for unit
can can Name
codes
partsparts
fromfrom
the Parts
Catalog,
identification
the Parts
Catalog, be used
identification
to to colorcolor
be used
check
the first
pagepage
of the
maymay
be used
check
the first
of the confirm
be used
the the and and
confirm
partsparts
list, list,
the code
nextnext
to to model
thanthan
one one
the code
for more
yearyear for more
model
the part
number,
and and
color.
the part
number,
color.
of the
of unit.
the unit. paintpaint
this this
chartchart
for color
verification.
for color
verification.
PAGE
4 of4 6of 6
PAGE
N/A N/A
– Not
Available.
– Not
Available.
*Paint
codecode
for ref*Paint
for reference
onlyonly
- Do- Do
erence
not paint
plastic
not paint
plastic
body.
body.
^5187
is not
^5187
is not
textured.
textured.
Color-Rite
Paint
Code
Information:
Color-Rite
Paint
Code
Information:
10001000
series
codes
are base
coats.
series
codes
are base
coats.
50005000
series
codes
are color
coats.
series
codes
are color
coats.
All color
coats
mustmust
be clear
coated.
All color
coats
be clear
coated.
UseUse
low low
gloss
clearclear
for low
gloss
paint.
gloss
for low
gloss
paint.
2005 ATV Paint Reference Chart
MODEL
CODE
MODEL
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
SPORT
“660R Raptor” Special Edition
YFM660RSET
5LPT
Sport Camo
Body*
Frame
Front Bumper
Wheel
Dark Gray Metallic E
Silver 8
Silver 8
No paint
0952
0895
0895
(DGME)
(S8)
(S8)
“660R Raptor”
YFM660RT
5LPP
Team Yamaha Blue /
White (L)
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
Silver 8
no paint
0583
0895
0895
(DPBSE) 5829
(S8)
5265
(S8)
5265
White /
Red
Body (Primary)*
Body (Secondary)*
Frame
Front Bumper
Wheel
Bluish White Solid 1
Vivid Red Cocktail 7
Vivid Red Cocktail 7
Silver 8
no paint
0892
0580
0580
0895
(BWS1)
(VRC7)
(VRC7)
(S8)
5780
1300-1 + 5826
1300-1 + 5826
5265
5809
5135
5988
5265
(W)
TBA
5265
5265
“YFZ450” Special Edition
YFZ450SET
5TGA
Yellow/
Black
Body (Primary)*
Body (Secondary)*
Frame
Front Bumper
Wheel
Light Reddish Yellow Solid 1
Yamaha Black
Mat Black 2
Silver 8
no paint
0386
0033
0582
0895
(LYRS1)
(YB)
(MBL2)
(S8)
“YFZ450”
YFZ450T
5TG7
Team Yamaha Blue /
White (L)
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
Silver 8
no paint
0583
0895
0895
(DPBSE) 5829
(S8)
5265
(S8)
5265
White /
Red
Body*
Frame
Front Bumper
Wheel
Bluish White Solid 1
Vivid Red Cocktail 7
Silver 8
no paint
0892
0580
0895
(BWS1)
(VRC7)
(S8)
5780
1300-1 + 5826
5265
TBA
5988
5265
(W)
“Banshee” Special Edition
YFZ350SET
5FKY
Black
Body*
Frame
Front Bumper
Wheel
Black Metallic J
Mat Black 2
Silver 8
no paint
0906
0582
0895
(SMJ)
(MBL2)
(S8)
“Banshee”
YFZ350T
5FKV
Team Yamaha Blue /
White (L)
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
Silver 8
no paint
0583
0895
0895
(DPBSE) 5829
(S8)
5265
(S8)
5265
White /
Red
Body (Primary)*
Body (Secondary)*
Frame
Front Bumper
Wheel
Bluish White Solid 1
Vivid Red Cocktail 7
Vivid Red Cocktail 7
Silver 8
no paint
0892
0580
0580
0895
(BWS1)
VRC7)
(VRC7)
(S8)
5780
1300-1 + 5826
1300-1 + 5826
5265
TBA
5988
(W)
“Raptor 350” Special Edition
YFM350RSET
5YT4
Grey
Body*
Frame
Front Bumper
Wheel
Dark Gray Metallic E
Mat Black 2
no paint
no paint
0952
0582
(DGME)
(MBL2)
“Raptor 350”
YFM350RT
5YT5
Team Yamaha Blue /
White (L)
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
no paint
no paint
0583
0895
(DPBSE) 5829
(S8)
5265
White /
Red
Body (Primary)*
Body (Secondary)*
Frame
Front Bumper
Wheel
Bluish White Solid 1
Romantique Rouge
Vivid Red Cocktail 7
no paint
no paint
0892
00TR
0580
(BWS1)
(RTR
(VRC7)
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
Model
codes can
be used to
confirm the
model year
of the unit.
(W)
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
*Paint code for reference only - Do
not paint plastic
body.
5780
5650
1300-1 + 5826
TBA – To Be
Announced
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
2005 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
SPORT (CONT’D)
“Blaster”
YFS200T
5VM5
Team Yamaha Blue /
White (L)
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
Silver 8
Silver
0583
0895
0895
0035
(DPBSE)
(S8)
(S8)
(SL)
5829
5265
5265
5616
White /
Red
Body*
Frame
Front Bumper
Wheel
Bluish White Solid 1
Vivid Red Cocktail 7
Silver 8
Silver
0892
0580
0895
0035
(BWS1)
(VRC7)
(S8)
(SL)
5780
1300-1 + 5826
5265
5616
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier
Wheel
Pastel Deep Green
Yamaha Black
Mat Black 2
Mat Black 2
Silver
00K0
0033
0582
0582
0035
(PDG)
(YB)
(MBL2)
(MBL2)
(SL)
5822
5135
5988
5988
5616
Steel Blue (L)
Body*
Frame
Front Bumper
Carrier
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Mat Black 2
Mat Black 2
Silver
0891
0033
0582
0582
0035
(DPBSN)
(YB)
(MBL2)
(MBL2)
(SL)
5290
5135
5988
5988
5616
Team Yamaha Blue /
White (L)
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Silver 8
Silver
0583
0033
0895
0035
(DPBSE)
(YB)
(S8)
(SL)
5829
5135
5265
5616
White /
Red
Body (Primary)*
Body (Secondary)*
Frame
Front Bumper
Wheel
Bluish White Solid 1
Romantique Rouge
Yamaha Black
Silver 8
Silver
0892
00TR
0033
0895
0035
(BWS1)
(RTR)
(YB)
(S8)
(SL)
5780
5650
5135
5265
5616
Team Yamaha Blue /
White (L)
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Silver 8
Silver
0583
0033
0895
0035
(DPBSE)
(YB)
(S8)
(SL)
5829
5135
5265
5616
White /
Red
Body (Primary)*
Body (Secondary)*
Frame
Front Bumper
Wheel
Bluish White Solid 1
Romantique Rouge
Yamaha Black
Silver 8
Silver
0892
00TR
0033
0895
0035
(BWS1)
(RTR)
(YB)
(S8)
(SL)
5780
5650
5135
5265
5616
(W)
YOUTH
“Grizzly 80”
YFM80GT
“Raptor 80”
YFM80RT
“Raptor 50”
YFM50RT
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
PAGE 6 of 6
2D31
5THB
5FY4
Model
codes can
be used to
confirm the
model year
of the unit.
(W)
(W)
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
ROUTE TO:
*Paint code for reference only - Do
not paint plastic
body.
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.
SERVICE PARTS WARRANTY SALES
2005 ATV Service Literature
2005 ATV Service Literature
©2005 YAMAHA MOTOR CORPORATION, USA
2005 MODELS
ATV Primary ID Numbers
The following is a comprehensive listing of Primary ID numbers for 2005 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
YFM50RT
Raptor 50
Displacement
49cc
Model Code
5YF
Starting PID No.
AA013-0007523
YFM80RT
Raptor 80
79cc
5TH
AB02Y-0030027
YFM80GT
Grizzly 80
79cc
2D3
AB03Y-0000011
YFM125GT
Grizzly 125
124cc
1C5
AE02Y-0002513
YFM125GHT
Grizzly 125 (Hunter Green)
124cc
1C5
AE02Y-0002513
YFS200T
Blaster
195cc
5VM
AG023-0026699
YFM250BT
Bruin 250 2WD
230cc
1P01
AG01Y-0112201
YFM350RT
Raptor 350
348cc
5YT
AH12Y-0004796
YFM350RSET
Raptor 350 SE (Special Edition)
348cc
5YT
AH12Y-0017518
YFM35FXT
Wolverine 4WD
348cc
4KB
AH04Y-0018609
YFZ350T
Banshee
347cc
5FK
3GG03-0057019
YFZ350SET
Banshee SE (Special Edition)
347cc
5FK
3GG03-0057019
YFM35BAT
Bruin 350 Auto 2WD
348cc
5WH
YFM35FAT
Bruin 350 Auto 4WD
348cc
5UH
AH09Y-0012301
YFM35FAHT
Bruin 350 Auto 4WD (Hunter Edition)
348cc
5UH
AH13Y-0000101
AH06Y-0052201
AH10Y-0007701
YFM40FT
Big Bear 400 4WD
386cc
5FU
YFM4FAT
Kodiak 400 4WD
401cc
1P1
AJ15Y-0000101
YFM4FAHT
Kodiak 400 4WD (Hunter Edition)
401cc
1P1
AJ15Y-0000101
YFM45FAT
Kodiak 450 4WD
421cc
1D9
AJ14Y-0000101
YFM45FAHT
Kodiak 450 4WD (Realtree Hardwoods® Hunter
Edition)
421cc
1D9
AJ16Y-0000101
YFZ450T
YFZ450
439cc
5TG
AJ11Y-0023898
YFZ450RSET
YFZ450 SE (Special Edition)
439cc
5TG
AJ11Y-0023898
YFM660RT
660R Raptor
660cc
5LP
AM01Y-0064904
YFM660RSET
660R Raptor SE (Special Edition)
660cc
5LP
AM01Y-0064904
YFM66FAT
Grizzly 660 4WD
660cc
5KM
AM03Y-0051677
YFM66FAHT
Grizzly 660 4WD (Realtree Hardwoods Hunter
Edition)
660cc
5KM
AM03Y-0051677
YFM66FAHWT
Grizzly 660 4WD (Realtree Wetlands™ Hunter
Edition)
660cc
5KM
AM03Y-0051677
YFM66FASET
Grizzly 660 4WD (Special Edition)
660cc
5KM
AM03Y-0051677
®
ROUTE TO:
SERVICE PARTS WARRANTY SALES
PAGE 1 of 1
© 2004 YAMAHA MOTOR CORPORATION, U.S.A.
2004 MODELS
ATV Paint Reference Chart
This bulletin provides paint identification and ordering information for all 2004-model ATVs. All ATV paint
may be ordered through Color Rite:
Color Rite Distribution Company now offers two ordering locations for your convenience. Color Rite East
is 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 Company
Color Rite East
123 Blaine St.
East Bangore, PA 18013
800-358-1882 - Order
610-588-7355 - Tech
610-588-1570 - Fax
Color Rite Dist. Co. (West)
1817 E. Ave. Q, Ste. C-24
Palmdale, CA 93550
800-736-7980 - Order
661-266-1944 - Tech
661-266-0286 - Fax
E-Mail: colorritewtr@earthlink.net
Web Site: www.color-rite.com.
As an added benefit, orders received by 2:00 pm (Eastern Standard Time for Color Rite East and Pacific
Standard Time for Color Rite West) will be shipped the same day.
For previous model year paint information, please refer to the following:
•
•
•
•
•
•
(’91~’99)
(’91~’99)
(’99~’00)
(2001)
(2002)
(2003)
Paint Reference Guide (P/N: LIT-10030-PC-99)
Summer ’99 Paint Chart Reference Guide (P/N: LIT-10030-PC-2K)
ATV Paint Reference Chart (Technical Bulletin AT2001-005)
ATV Paint Reference Chart (Technical Bulletin AT2001-003)
ATV Paint Reference Chart (Technical Bulletin AT2001-009)
ATV Paint Reference Chart (Technical Bulletin AT2003-002)
When ordering, please provide Color Rite with the Year, Model, and Paint Code. Remember to provide
call 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 web page:
www.color-rite.com
NOTE: The following paint chart is also very useful when ordering pre-painted and plastic body parts
from the parts catalog. Paint codes are generally listed next to the part number of the pre-painted or
plastic body part. This chart can be used to confirm the color of the part you are ordering. The Sales
color name may be used for more than one paint color.
PAGE 1 of 6
2004 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
UTILITY
Grizzly 660 Auto 4x4
YFM660FHS
Realtree Hardwoods® Camo
Hunter Edition
5KMM
Grizzly 660 Auto 4x4
YFM660FHSWL
Realtree® Wetlands™ Camo
Hunter Edition
Hunter Edition
(Realtree Hardwoods®
Camouflage)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Low Gloss Black
Chijimi Black
Low Gloss Black
0033
0098
00W0
0098
(YB)
(LGB)
(WVB)
(LGB)
5135
5654
5187^
5654
5KMN
Hunter Edition
Body*
(Advantage® Wetlands™ Frame
Camouflage)
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Low Gloss Black
Chijimi Black
Low Gloss Black
0033
0098
00W0
0098
(YB)
(LGB)
(WVB)
(LGB)
5135
5654
5187^
5654
Grizzly 660 Limited Edition
Auto 4x4
YFM660FLES
5KMP
Limited Edition Metallic
Red
Body
Frame
Front Bumper
Carrier (F&R)
Wheel
Dull Red Metallic D
Yamaha Black
Low Gloss Black
Chijimi Black
No paint
0779
0033
0098
00W0
(DRMD)
(YB)
(LGB)
(WVB)
1165 + 5165
5135
5654
5187^
Grizzly 660 Auto 4x4
YFM660FS
5KMH
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Chijimi Black
No paint
00K0
0033
00MA
00W0
(PDG)
(YB)
(TGM)
(WVB)
5822
5135
5860
5187^
Steel Blue
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Titanic Gray Metallic
Chijimi Black
No paint
0891
0033
00MA
00W0
(DPBSN)
(YB)
(TGM)
(WVB)
5290
5135
5860
5187^
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Chijimi Black
No paint
00TR
0033
00MA
00W0
(RTR)
(YB)
(TGM)
(WVB)
5650
5135
5860
5187^
Kodiak 450 4x4 Ultramatic
YFM45FAHS
Realtree Hardwoods® Camo
Hunter Edition
5NDC
Hunter Edition
(Realtree Hardwoods®
Camouflage)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0033
00W0
00W0
0098
(YB)
(WVB)
(WVB)
(LGB)
5135
5187^
5187^
5654
Kodiak 450 4X4 Ultramatic
YFM45FAS
5ND6
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00K0
0033
00W0
00W0
00MA
(PDG)
(YB)
(WVB)
(WVB)
(TGM)
5822
5135
5187^
5187^
5860
Steel Blue
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
0891
0033
00W0
00W0
00MA
(DPBSN)
(YB)
(WVB)
(WVB)
(TGM)
5290
5135
5187^
5187^
5860
Kodiak 400 4x4 Ultramatic
YFM4FAHS
Realtree Hardwoods® Camo
Hunter Edition
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the parts list,
the code next to the part
number, and this chart for
color verification.
PAGE 2 of 6
5TEA
Model
codes can
be used to
confirm the
model year
of the unit.
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00TR
0033
00W0
00W0
00MA
(RTR)
(YB)
(WVB)
(WVB)
(TGM)
5650
5135
5187^
5187^
5860
Hunter Edition
(Realtree Hardwoods®
Camouflage)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0033
00W0
00W0
0098
(YB)
(WVB)
(WVB)
(LGB)
5135
5187^
5187^
5654
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
*Paint code for reference only - Do
not paint plastic
body.
N/A - Not Available.
^5187 is not
textured.
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.
2004 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
UTILITY (CONT’D)
Kodiak 400 Ultramatic 4X4
YFM4FAS
Kodiak 400 Ultramatic 2WD
YFM4AS
Big Bear 400 4X4
YFM40FS
Big Bear 400 2WD
YFM40S
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
5TE6
5VH5
5FUE
5GWB
Model
codes can
be used to
confirm the
model year
of the unit.
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00K0
0033
00W0
00W0
0098
(PDG)
(YB)
(WVB)
(WVB)
(LGB)
5822
5135
5187^
5187^
5654
Steel Blue
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0891
0033
00W0
00W0
0098
(DPBSN)
(YB)
(WVB)
(WVB)
(LGB)
5290
5135
5187^
5187^
5654
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00TR
0033
00W0
00W0
0098
(RTR)
(YB)
(WVB)
(WVB)
(LGB)
5650
5135
5187^
5187^
5654
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00K0
0033
00W0
00W0
0098
(PDG)
(YB)
(WVB)
(WVB)
(LGB)
5822
5135
5187^
5187^
5654
Steel Blue
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0891
0033
00W0
00W0
0098
(DPBSN)
(YB)
(WVB)
(WVB)
(LGB)
5290
5135
5187^
5187^
5654
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00TR
0033
00W0
00W0
0098
(RTR)
(YB)
(WVB)
(WVB)
(LGB)
5650
5135
5187^
5187^
5654
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00K0
0033
00W0
00W0
0098
(PDG)
(YB)
(WVB)
(WVB)
(LGB)
5822
5135
5187^
5187^
5654
Steel Blue
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0891
0033
00W0
00W0
0098
(DPBSN)
(YB)
(WVB)
(WVB)
(LGB)
5290
5135
5187^
5187^
5654
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00TR
0033
00W0
00W0
0098
(RTR)
(YB)
(WVB)
(WVB)
(LGB)
5650
5135
5187^
5187^
5654
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00K0
0033
00W0
00W0
0098
(PDG)
(YB)
(WVB)
(WVB)
(LGB)
5822
5135
5187^
5187^
5654
Steel Blue
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0891
0033
00W0
00W0
0098
(DPBSN)
(YB)
(WVB)
(WVB)
(LGB)
5290
5135
5187^
5187^
5654
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
*Paint code for reference only - Do
not paint plastic
body.
^5187 is not
textured.
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 3 of 6
2004
ATV
Paint
Reference
Chart
2004
ATV
Paint
Reference
Chart
MODEL
MODEL
MODEL
MODEL
CODE
CODE
SALES
SALES
COLOR
NAME
COLOR
NAME
COMPONENT
COMPONENT
PAINT
PAINT
COLOR
NAME
COLOR
NAME
YAMAHA
RITE
YAMAHA COLOR
COLOR
RITE
PAINT
CODE
CODE
PAINT
CODE PAINT
PAINT
CODE
UTILITY
(CONT’D)
UTILITY
(CONT’D)
Bruin
350 350
Auto
4x4 4x4
5UH3
Bruin
Auto
5UH3
YFM35FAHS
YFM35FAHS
®
®
Realtree
Hardwoods
Camo
Camo
Realtree
Hardwoods
Hunter
Edition
Hunter
Edition
Bruin
350 350
Auto
4x4 4x4
Bruin
Auto
YFM35FAS
YFM35FAS
Bruin
350 350
Auto
2WD2WD
Bruin
Auto
YFM35AS
YFM35AS
Wolverine
4X44X4
Wolverine
YFM35FXS
YFM35FXS
BearTracker
BearTracker
YFM250XS
YFM250XS
C - Designates
C - Designates
California
Model
California
Model
5UH1
5UH1
5WH1
5WH1
4KBX
4KBX
4XEL
4XEL
Hunter
Edition
Body*
Hunter
Edition
Body*
®
® Frame
(Realtree
Hardwoods
(Realtree
Hardwoods
Frame
Camouflage)
Front
Bumper
Camouflage)
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
N/A N/A
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss Black
00330033(YB)(YB)
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
00980098(LGB)
(LGB)
51355135
5187^
5187^
5187^
5187^
56545654
Hunter
Green
Hunter
Green
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Pastel
Deep
Green
Pastel
Deep
Green
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
00K0
(PDG)
00K0(PDG)
00330033(YB)(YB)
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
00980098(LGB)
(LGB)
58225822
51355135
5187^
5187^
5187^
5187^
56545654
Steel
BlueBlue
Steel
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
DarkDark
Purplish
BlueBlue
SolidSolid
N N
Purplish
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
52905290
08910891(DPBSN)
(DPBSN)
00330033(YB)(YB) 51355135
(WVB)
5187^
00W0
(WVB) 5187^
00W0
(WVB)
5187^
00W0
(WVB) 5187^
00W0
00980098(LGB)
(LGB) 56545654
RedRed
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Romantique
Rouge
Romantique
Rouge
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
(RTR)
00TR
(RTR)
00TR
00330033(YB)(YB)
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
00980098(LGB)
(LGB)
56505650
51355135
5187^
5187^
5187^
5187^
56545654
Hunter
Green
Hunter
Green
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Pastel
Deep
Green
Pastel
Deep
Green
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
00K0
(PDG)
00K0(PDG)
00330033(YB)(YB)
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
00980098(LGB)
(LGB)
58225822
51355135
5187^
5187^
5187^
5187^
56545654
Steel
BlueBlue
Steel
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
DarkDark
Purplish
BlueBlue
SolidSolid
N N
Purplish
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
52905290
08910891(DPBSN)
(DPBSN)
00330033(YB)(YB) 51355135
(WVB)
5187^
00W0
(WVB) 5187^
00W0
(WVB)
5187^
00W0
(WVB) 5187^
00W0
00980098(LGB)
(LGB) 56545654
RedRed
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Romantique
Rouge
Romantique
Rouge
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
(RTR)
00TR
(RTR)
00TR
00330033(YB)(YB)
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
00980098(LGB)
(LGB)
Team
Yamaha
BlueBlue
Team
Yamaha
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(R) (R)
Carrier
Wheel
Wheel
Deep
Purplish
BlueBlue
SolidSolid
E E
Deep
Purplish
Yamaha
Black
Yamaha
Black
Silver
8 8
Silver
Yamaha
Black
Yamaha
Black
Silver
Silver
58295829
05830583(DPBSE)
(DPBSE)
00330033(YB)(YB) 51355135
52655265
08950895(S8)(S8)
00330033(YB)(YB) 51355135
56165616
00350035(SL)(SL)
Black
Black
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(R) (R)
Carrier
Wheel
Wheel
Yamaha
Black
Yamaha
Black
Yamaha
Black
Yamaha
Black
Mat Mat
Black
2 2
Black
Yamaha
Black
Yamaha
Black
LowLow
Gloss
Black
Gloss
Black
00330033(YB)(YB) 51355135
00330033(YB)(YB) 51355135
05820582(MBL2)
(MBL2) 59885988
00330033(YB)(YB) 51355135
00980098(LGB)
(LGB) 56545654
Hunter
Green
Hunter
Green
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Pastel
Deep
Green
Pastel
Deep
Green
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
00K0
(PDG)
00K0(PDG)
00330033(YB)(YB)
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
00980098(LGB)
(LGB)
Steel
BlueBlue
Steel
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
DarkDark
Purplish
BlueBlue
SolidSolid
N N
Purplish
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
52905290
08910891(DPBSN)
(DPBSN)
00330033(YB)(YB) 51355135
(WVB)
5187^
00W0
(WVB) 5187^
00W0
(WVB)
5187^
00W0
(WVB) 5187^
00W0
00980098(LGB)
(LGB) 56545654
RedRed
Body*
Body*
Frame
Frame
Front
Bumper
Front
Bumper
Carrier
(F&R)
Carrier
(F&R)
Wheel
Wheel
Romantique
Rouge
Romantique
Rouge
Yamaha
Black
Yamaha
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
Chijimi
Black
LowLow
Gloss
Black
Gloss
Black
(RTR)
00TR
(RTR)
00TR
00330033(YB)(YB)
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
(WVB)
00W0
00980098(LGB)
(LGB)
The The
Sales
Color
Sales
Color
Model
Model
is forisunit
Name
for unit
codes
can can Name
codes
identification
identification
be used
to to colorcolor
be used
NOTE:
When
ordering
maymay
be used
NOTE:
When
ordering
be used
confirm
the the and and
confirm
pre-painted
or plastic
bodybody model
thanthan
one one
pre-painted
or plastic
for more
yearyear for more
model
partsparts
fromfrom
the Parts
Catalog,
color.
the Parts
Catalog, of the
color.
of unit.
the unit. paintpaint
check
the first
pagepage
of the
check
the first
of the
partsparts
list, list,
the code
nextnext
to to
the code
the part
number,
and and
the part
number,
this this
chartchart
for color
verification.
for color
verification.
PAGE
4 of4 6of 6
PAGE
N/A N/A
- Not- Not
Available.
Available.
*Paint
codecode
for ref*Paint
for reference
onlyonly
- Do- Do
erence
not paint
plastic
not paint
plastic
body.
body.
56505650
51355135
5187^
5187^
5187^
5187^
56545654
58225822
51355135
5187^
5187^
5187^
5187^
56545654
56505650
51355135
5187^
5187^
5187^
5187^
56545654
^5187
is not
^5187
is not
textured.
textured.
Color-Rite
Paint
Code
Information:
Color-Rite
Paint
Code
Information:
10001000
series
codes
are base
coats.
series
codes
are base
coats.
50005000
series
codes
are color
coats.
series
codes
are color
coats.
All color
coats
mustmust
be clear
coated.
All color
coats
be clear
coated.
UseUse
low low
gloss
clearclear
for low
gloss
paint.
gloss
for low
gloss
paint.
2004 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
UTILITY (CONT’D)
125 Grizzly
YFM125S
Breeze
YFA1S/C
1C51
5VJ4/5VJ5
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Mat Black 2
Mat Black 2
Silver
00K0
0033
0582
0582
0035
(PDG)
(YB)
(MBL2)
(MBL2)
(SL)
5822
5135
5988
5988
5616
Steel Blue
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Puplish Blue Solid N
Yamaha Black
Mat Black 2
Mat Black 2
Silver
0891
0033
0582
0582
0035
(DPBSN)
(YB)
(MBL2)
(MBL2)
(SL)
5290
5135
5988
5988
5616
Team Yamaha Blue
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Yamaha Black
Silver
0583
0033
0033
0035
(DPBSE)
(YB)
(YB)
(SL)
5829
5135
5135
5616
Hunter Green
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Yamaha Black
Silver
00K0
0033
0033
0035
(PDG)
(YB)
(YB)
(SL)
5822
5135
5135
5616
Team Yamaha Blue /
White
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
Silver 8
no paint
0583
0895
0895
(DPBSE)
(S8)
(S8)
5829
5265
5265
White /
Red
Body*
Body
Frame
Front Bumper
Wheel
Bluish White Solid 1
Vivid Red Cocktail 7
Vivid Red Cocktail 7
Silver
no paint
0892
0580
0580
0035
(BWS1)
(VRC7)
(VRC7)
(SL)
5780
5826
5826
5616
SPORT
660R Raptor
YFM660RS
5LPF
660R Raptor Limited Edition
YFM660RLES
5LPJ
Black / Yellow
Body*
Body
Frame
Front Bumper
Wheel
Yamaha Black
Silver 3
Mat Black 2
Mat Black 2
Low Gloss Black
0033
0791
0582
0582
0098
(YB)
(S3)
(MBL2)
(MBL2)
(LGB)
5135
5175
5988
5988
5654
YFZ450
YFZ450S
5TG1
Team Yamaha Blue /
White
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
Silver 8
no paint
0583
0895
0895
(DPBSE)
(S8)
(S8)
5829
5265
5265
White /
Red
Body*
Body
Frame
Front Bumper
Wheel
Bluish White Solid 1
Vivid Red Cocktail 7
Vivid Red Cocktail 7
Silver 8
no paint
0892
0580
0580
0895
(BWS1)
(VRC7)
(VRC7)
(S8)
5780
5826
5826
5265
YFZ450 Limited Edition
YFM450LES
5TG4
Black / Yellow
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Mat Titan 2
Mat Titan 2
Low Gloss Black
0033
0826
0826
0098
(YB)
(MT2)
(MT2)
(LGB)
5135
5997
5997
5654
Raptor 350
YFM350S
5YT1
Team Yamaha Blue /
White
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
no paint
no paint
0583
0895
(DPBSE)
(S8)
5829
5265
White /
Red
Body*
Body
Frame
Front Bumper
Wheel
Bluish White Solid 1
Romantique Rouge
Vivid Red Cocktail 7
no paint
no paint
0892
00TR
0580
(BWS1)
(RTR)
(VRC7)
5780
5650
5826
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
Model
codes can
be used to
confirm the
model year
of the unit.
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
*Paint code for reference only - Do
not paint plastic
body.
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
2004 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
SPORT (CONT’D)
Banshee
YFZ350S
5FKP
Team Yamaha Blue /
White
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
Silver 8
no paint
0583
0895
0895
(DPBSE)
(S8)
(S8)
5829
5265
5265
White /
Red
Body*
Body
Frame
Front Bumper
Wheel
Bluish White Solid 1
Vivid Red Cocktail 7
Vivid Red Cocktail 7
Silver 8
no paint
0892
0580
0580
0895
(BWS1)
(VRC7)
(VRC7)
(S8)
5780
5826
5826
5265
Banshee Limited Edition
YFZ350LES
5FKT
Black / Yellow
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Mat Black 2
Mat Black 2
Low Gloss Black
0033
0582
0582
0098
(YB)
(MBL2)
(MBL2)
(LGB)
5135
5988
5988
5654
Warrior
YFM35XS(C)
5NFB /
5NFC
Team Yamaha Blue /
White
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
Silver 8
no paint
0583
0895
0895
(DPBSE)
(S8)
(S8)
5829
5265
5265
White /
Red
Body*
Frame
Front Bumper
Wheel
Bluish White Solid 1
Vivid Red Cocktail 7
Silver 8
no paint
0892
0580
0895
(BWS1)
(VRC7)
(S8)
5780
5826
5265
Team Yamaha Blue /
White
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver 8
Silver 8
Silver
0583
0895
0895
0035
(DPBSE)
(S8)
(S8)
(SL)
5829
5265
5265
5616
White /
Red
Body*
Frame
Front Bumper
Wheel
Bluish White Solid 1
Vivid Red Cocktail 7
Silver 8
Silver
0892
0580
0895
0035
(BWS1)
(VRC7)
(S8)
(SL)
5780
5826
5265
5616
Team Yamaha Blue /
White
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Silver 8
Silver
0583
0033
0895
0035
(DPBSE)
(YB)
(S8)
(SL)
5829
5135
5265
5616
White /
Red
Body*
Body
Frame
Front Bumper
Wheel
Bluish White Solid 1
Romantique Rouge
Yamaha Black
Silver 8
Silver
0892
00TR
0033
0895
0035
(BWS1)
(RTR)
(YB)
(S8)
(SL)
5780
5650
5135
5265
5616
Team Yamaha Blue /
White
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Silver 8
Silver
0583
0033
0895
0035
(DPBSE)
(YB)
(S8)
(SL)
5829
5135
5265
5616
White /
Red
Body*
Body
Frame
Front Bumper
Wheel
Bluish White Solid 1
Romantique Rouge
Yamaha Black
Silver 8
Silver
0892
00TR
0033
0895
0035
(BWS1)
(RTR)
(YB)
(S8)
(SL)
5780
5650
5135
5265
5616
Blaster
YFS200S
5VM3
YOUTH
Raptor 80
YFM80WS
Raptor 50
YFM50S
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
PAGE 6 of 6
5TH8
5YF1
Model
codes can
be used to
confirm the
model year
of the unit.
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
ROUTE TO:
*Paint code for reference only - Do
not paint plastic
body.
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.
SERVICE PARTS WARRANTY SALES
© 2004 YAMAHA MOTOR CORPORATION, U.S.A.
2004 MODELS
ATV Service Literature
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 listed in the chart below can be ordered from Crestec Los Angeles, Inc. (Ph: 1-888-530-9446, FAX: 1-310527-5835). This bulletin also lists other publications related to your dealership operation (see page 3),
which can be ordered from Yamaha Parts and Accessories.
Model
Model
Name
Owner’s
Manual
Service Manual
(Main)
Supplements
(Supplements Only)
Compilation Manual
(Main & Supplements)
Assembly
Manual
YFM50WS
Raptor 50
LIT-11626-17-13
LIT-11616-17-13
YFM80WS
Raptor 80
LIT-11626-17-12
YFM80WD~M
LIT-11616-YF-80
YFM80WP
LIT-11616-15-38
LIT-11616-YF-81
LIT-11666-17-13
YFM80WP
LIT-11666-15-38
YFA1S
Breeze
LIT-11626-17-02
YFA1W(~N)
LIT-11616-YF-00
YFA1P
LIT-11616-15-08
LIT-11616-YF-01
LIT-11666-17-02
YFA1SC
Breeze (Calif.)
LIT-11626-17-02
YFA1W(~N)
LIT-11616-YF-00
YFA1P
LIT-11616-15-08
LIT-11616-YF-01
LIT-11666-17-02
YFM125S
Grizzly 125
LIT-11626-17-56
YFA1W(~N)
LIT-11616-YF-00
YFA1P
LIT-11616-15-08
YFM125S
LIT-11616-17-56
LIT-11616-GZ-12
LIT-11666-17-56
YFS200S
Blaster
LIT-11626-17-07
YFS200U
LIT-11616-07-20
YFS200P
LIT-11616-15-05
YFS200R
LIT-11616-16-37
LIT-11616-BL-20
LIT-11666-17-07
YFM25XS
BearTracker
LIT-11626-17-22
YFM250XL
LIT-11616-12-01
YFM250XN
LIT-11616-14-17
YFM250XP
LIT-11616-15-03
LIT-11616-BT-25
YFM250XL
LIT-11666-12-01
YFM35AS
Bruin 350 2WD
YFM400FAR
LIT-11616-16-02
YFM350AS
LIT-11616-17-33
LIT-11616-BN-20
LIT-11666-17-33
YFM350S
Raptor 350
LIT-11626-17-57
YFM350XA(~N)
LIT-11616-YM-37
YFM350XP
LIT-11616-15-09
YFM350ZS
LIT-11616-17-57
LIT-11616-RP-35
LIT-11666-17-57
YFM35FAS
Bruin 350 4x4
LIT-11626-17-32
YFM400FAR
LIT-11616-16-02
YFM350AS
LIT-11616-17-32
LIT-11616-BN-35
LIT-11666-17-32
YFM35FAHS Bruin 350 4x4
Hardwoods®
Hunter
LIT-11626-17-32
YFM400FAR
LIT-11616-16-02
YFM350AS
LIT-11616-17-32
LIT-11616-BN-35
LIT-11666-17-32
YFM35FXS
LIT-11626-17-03
YFM350FXG(~M)
LIT-11616-FX-36
LIT-11616-FX-37
YFM35FXG
LIT-11666-09-58
Wolverine 4x4
LIT-11626-17-33
YFM350FXN
LIT-11616-14-02
YFM350FXP
LIT-11616-15-07
PAGE 1 of 3
2004 ATV Service Literature
Model
Name
Model
Owner’s
Manual
Service Manual
(Main)
Supplements
(Supplements Only)
Compilation Manual
(Main & Supplements)
Assembly
Manual
YFM35XS
Warrior
LIT-11626-17-06
YFM350XA(~N)
LIT-11616-YM-37
YFM350XP
LIT-11616-15-09
LIT-11616-YM-38
LIT-11666-17-06
YFM35XSC
Warrior (Calif.)
LIT-11626-17-06
YFM350XA(~N)
LIT11616-YM-37
YFM35XP
LIT-11616-15-09
LIT-11616-YM-38
LIT-11666-17-06
YFZ350S
Banshee
LIT-11626-17-04
YFZ350T(~N)
LIT-11616-YF-36
YFZ350P
LIT-11616-15-04
LIT-11616-YF-37
LIT-11666-17-04
YFZ350LES
Banshee
Limited Edition
LIT-11626-17-04
YFZ350T(~N)
LIT-11616-YF-36
YFZ350P
LIT-11616-15-04
LIT-11616-YF-37
LIT-11666-17-04
YFM4AS
Kodiak 400 2WD
Ultramatic
LIT-11626-17-18
YFM400FAR
LIT-11616-16-02
YFM400AR
LIT-11616-16-35
LIT-11616-KD-20
YFM400AR
LIT-11666-16-35
YFM4FAS
Kodiak 400 4x4
Ultramatic
LIT-11626-17-17
YFM400FAR
LIT-11616-16-02
YFM400FAR
LIT-11666-16-02
YFM4FAHS
Kodiak 400 4x4
Hunter Ultramatic
LIT-11626-17-17
YFM400FAR
LIT-11616-16-02
YFM400FAR
LIT-11666-16-02
YFM40S
Big Bear 400 2WD LIT-11626-17-08 YFM400FWNM(~N)
LIT-11616-BB-2K
YFM400P
LIT-11616-15-21
LIT-11616-BB-20
YFM400M
LIT-11666-13-34
YFM40FS
Big Bear 400 4x4
LIT-11626-17-10
YFM400FM
LIT-11616-BB-2K
YFM40FP
LIT-11616-15-22
LIT-11616-BB-40
YFM400FWNM
LIT-11666-13-22
YFM45FAS
Kodiak 450 4x4
Ultramatic
LIT-11626-17-25
YFM450FAR
LIT-11616-16-01
YFM450FAS
LIT-11616-17-25
LIT-11616-KD-45
YFM450FAR
LIT-11666-16-01
YFM45FAHS
Kodiak 450 4x4
Hardwoods®
LIT-11626-17-25
YFM450FAR
LIT-11616-16-01
LIT-11616-17-25
Hunter Ultramatic
YFM450FAS
LIT-11616-KD-45
YFM450FAR
LIT-11666-16-01
YFZ450S
YFZ450
LIT-11626-17-11
LIT-11616-17-11
YFM660FS
Grizzly 660
LIT-11626-17-14
YFM660FP
LIT-11616-15-01
YFM660FR
LIT-11616-16-34
YFM660FS
LIT-11616-17-14
LIT-11616-GZ-66
YFM660FP
LIT-11666-15-01
YFM660FHS
Grizzly 660
Hardwoods®
Hunter
LIT-11626-17-14
YFM660FP
LIT-11616-15-01
YFM660FR
LIT-11616-16-34
YFM660FS
LIT-11616-17-14
LIT-11616-GZ-66
YFM660FP
LIT-11666-15-01
YFM660FLES
Grizzly 660
Limited Edition
LIT-11626-17-14
YFM660FP
LIT-11616-15-01
YFM660FR
LIT-11616-16-34
YFM660FS
LIT-11616-17-14
LIT-11616-GZ-66
YFM660FP
LIT-11666-15-01
YFM660FHSWL Grizzly 660
Wetlands™
LIT-11626-17-14
YFM660FP
LIT-11616-15-01
YFM660FR
LIT-11616-16-34
YFM660FS
LIT-11616-17-14
LIT-11616-GZ-66
YFM660FP
LIT-11666-15-01
YFM660RS
660R Raptor
LIT-11626-17-05
YFM660RN
LIT-11616-14-21
YFM660RP
LIT-11616-15-31
LIT-11616-RP-66
LIT-11666-17-05
YFM660RLES
660R Raptor
Limited Edition Black
LIT-11626-17-05
YFM660RN
LIT-11616-14-21
YFM660RP
LIT-11616-15-31
LIT-11616-RP-66
LIT-11666-17-05
PAGE 2 of 3
LIT-11666-17-11
2004 ATV Service Literature
OTHER PUBLICATIONS
Order the following publications from Yamaha Parts and Accessories:
CATEGORY
Consumer
PUBLICATIONS
PART NUMBER
2004 ATV Utility Accessory Brochure
LIT-ATCAT-00-04
2004 Sport ATV Accessory Brochurre
LIT-ATCAT-SP-04
2004 ATV Full Line Mini Brochure
LIT-ATVMI-N1-04
2004 Sports ATVs Brochure
LIT-11104-SP-RT
2004 Utility ATVs Brochure
LIT-11104-UT-IL
Tips and Practice Guide for the ATV Rider
LIT-11626-15-49
Ride Safe, Ride Smart Videotape
VID-17299-00-00
ATV Rally CD-ROM
LIT-17299-CD-00
ATV Warranty Statement*
General Service and Warranty
Yamaha Extended Service
(Y.E.S.)
LIT-11790-002-03
ATV Safety Alert
LIT-17451-02-03
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-17161-01-2K
2004 MCY/ATV/SxS Technical Update Book
LIT-17500-00-04
2004 MCY/ATV/SxS Technical Update CD
LIT-CDTEC-MS-04
Parts System Handbook
LIT-10080-07-04
Warranty Labor Rate Change Request
LIT-11791-02-02
’95 ~ ’04 ATV Service Data Book
LIT-SDATA-AT-00
2004 ATV Flat Rate Manual
LIT-17750-00-04
Warranty and Y.E.S. Handbook
LIT-11760-00-03
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-11590-00-04
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
VID-10660-00-78
Y.E.S. Motorsports Poster
LIT-11580-00-41
Model Year Suffix Letter Chart
Model Year
Suffix Letter
1987
T
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
ROUTE TO:
SERVICE PARTS WARRANTY SALES
PAGE 3 of 3
© 2004 YAMAHA MOTOR CORPORATION, U.S.A.
2004 MODELS
ATV Primary ID Numbers
The following is a comprehensive listing of Primary ID numbers for 2004 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
YFM50S
Raptor 50
Displacement
Model Code
49cc
5YF1
Starting PID No.
AA013-0000014
YFM80WS
Raptor 80
79cc
5TH8
AB02Y-0022092
YFA-1S
Breeze
124cc
5VJ4
AE013-0015823
YFA-1SC
Breeze (California Model)
124cc
5VJ5
AE01Y-0002636
YFM125S
Grizzly 125
124cc
1C51
AE02Y-0000013
YFS200S
Blaster
195cc
5VM3
AG023-0014092
YFM25XS
BearTracker
230cc
4XEL
AG01Y-0103801
YFM350S
Raptor 350
348cc
5YT1
AH12Y-0000015
YFM35FXS
Wolverine 4WD
348cc
4KBX
AH04Y-0015688
YFM35XS
Warrior
348cc
5NFB
3GD03-0039676
YFM35XSC
Warrior (California Model)
348cc
5NFC
AH01Y-0007082
YFZ350S
Banshee
347cc
5FKP
3GG03-0049053
YFZ350LES
Banshee (Limited Edition)
347cc
5FKT
3GG03-0049053
YFM35AS
Bruin Auto 2WD
348cc
5WH1
AH10Y-0000101
YFM35FAS
Bruin Auto 4WD
348cc
5UH1
AH09Y-0000101
YFM35FAHS
Bruin Auto 4WD (Hunter Edition)
348cc
5UH3
AH11Y-0000101
YFM40S
Big Bear 400 2WD
386cc
5GWB
AH08Y-0003401
YFM40FS
Big Bear 400 4WD
386cc
5FUE
AH06Y-0047401
YFM4AS
Kodiak 400 2WD
401cc
5VH5
AJ08Y-0007802
YFM4FAS
Kodiak 400 4WD
401cc
5TE6
AJ07Y-0016301
YFM4FAHS
Kodiak 400 4WD (Hunter Edition)
401cc
5TEA
AJ13Y-0000101
YFM45FAS
Kodiak 450 4WD
421cc
5ND6
AJ06Y-0015601
YFM45FAHS
Kodiak 450 4WD (Realtree Hardwoods® Hunter
Edition)
421cc
5NDC
AJ12Y-0000101
YFZ450S
YFZ450
439cc
5TG1
AJ11Y-0000026
YFM660RS
660R Raptor
660cc
5LPF
AM01Y-0045700
YFM660RLERS
660R Raptor (Limited Edition)
660cc
5LPJ
AM01Y-0045700
YFM660FS
Grizzly 660 4WD
660cc
5KMH
AM03Y-0024941
YFM660FHS
Grizzly 660 4WD (Realtree Hardwoods® Hunter
Edition)
660cc
5KMM
AM03Y-0024941
YFM660FHSWL
Grizzly 660 4WD (Realtree Wetlands™ Hunter
Edition)
660cc
5KMN
AM03Y-0024941
YFM660FLES
Grizzly 660 4WD (Limited Edition)
660cc
5KMP
AM03Y-0024941
ROUTE TO:
SERVICE PARTS WARRANTY SALES
PAGE 1 of 1
© 2003 YAMAHA MOTOR CORPORATION, U.S.A.
2003 MODELS
ATV Paint Reference Chart
This bulletin provides paint identification and ordering information for all 2003-model ATVs. All ATV paint
may be ordered through Color Rite:
Color Rite Distribution Company
11603 Groveland Ave.
Whittier, CA 90604
For Info (562) 947-9796
Fax (562) 947-5087
To ORDER, CALL: (800) 736-7980
E-Mail: colorritewtr@earthlink.net
Web Site: www.color-rite.com.
When ordering, please provide Color Rite with the Year, Model, and Paint Code. Remember to provide
call back information for your dealership (e.g., phone number / fax / e-mail).
For previous model year paint information, please refer to the following:
●
●
●
●
●
(’91~’99)
(’91~’99)
(’99~’00)
(2001)
(2002)
Paint Reference Guide (P/N: LIT-10030-PC-99)
Summer ’99 Paint Chart Reference Guide (P/N: LIT-10030-PC-2K)
ATV Paint Reference Chart (Technical Bulletin AT2001-005)
ATV Paint Reference Chart (Technical Bulletin AT2001-003)
ATV Paint Reference Chart (Technical Bulletin AT2001-009)
A Model Application Guide providing detailed information by model year can be found at 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 parts
from the parts catalog. Paint codes are generally listed next to the part number of the pre-painted or
plastic body part. This chart can be used to confirm the color of the part you are ordering. The Sales
color name may be used for more than one paint color.
PAGE 1 of 6
2003 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
UTILITY
660 Grizzly
YFM660FHR
Realtree Hardwoods® Camo
Hunter Edition
5KM8
Hunter Edition
(Realtree Hardwoods®
Camouflage)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Low Gloss Black
Chijimi Black
Low Gloss Black
0033
0098
00W0
0098
(YB)
(LGB)
(WVB)
(LGB)
5135
5654
5187^
5654
660 Grizzly
YFM660FHR-H
Realtree® Wetlands™ Camo
Hunter Edition
5KMG
Hunter Edition
Body*
(Advantage® Wetlands™ Frame
Camouflage)
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Low Gloss Black
Chijimi Black
Low Gloss Black
0033
0098
00W0
0098
(YB)
(LGB)
(WVB)
(LGB)
5135
5654
5187^
5654
660 Grizzly Limited Edition
YFM660FRGY
5KMD
Limited Edition Metallic
Titanium
Body
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Gray Metallic A
Yamaha Black
Low Gloss Black
Chijimi Black
Low Gloss Black
0821
0033
0098
00W0
0098
(DGMA)
(YB)
(LGB)
(WVB)
(LGB)
5180
5135
5654
5187^
5654
660 Grizzly
YFM660FR
5KMA
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Chijimi Black
No paint
00K0
0033
00MA
00W0
(PDG)
(YB)
(TGM)
(WVB)
5822
5135
5860
5187^
Beige
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Chijimi Black
No paint
0598
0033
00MA
00W0
(DNYS1)
(YB)
(TGM)
(WVB)
5901
5135
5860
5187^
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Chijimi Black
No paint
00TR
0033
00MA
00W0
(RTR)
(YB)
(TGM)
(WVB)
5650
5135
5860
5187^
Kodiak 450 A 4x4 Ultramatic
YFM45FAHR
Realtree Hardwoods® Camor
Hunter Edition
5ND5
Hunter Edition
(Realtree Hardwoods®
Camouflage)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0033
00W0
00W0
0098
(YB)
(WVB)
(WVB)
(LGB)
5135
5187^
5187^
5654
Kodiak 450 4X4 Ultramatic
YFM45FAR
5ND1
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00K0
0033
00W0
00W0
00MA
(PDG)
(YB)
(WVB)
(WVB)
(TGM)
5822
5135
5187^
5187^
5860
Beige
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
0598
0033
00W0
00W0
00MA
(DNYS1)
(YB)
(WVB)
(WVB)
(TGM)
5901
5135
5187^
5187^
5860
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00TR
0033
00W0
00W0
00MA
(RTR)
(YB)
(WVB)
(WVB)
(TGM)
5650
5135
5187^
5187^
5860
Hunter Edition
(Realtree Hardwoods®
Camouflage)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0033
00W0
00W0
0098
(YB)
(WVB)
(WVB)
(LGB)
5135
5187^
5187^
5654
Kodiak 400 4x4 Ultramatic
YFM4FAHR
Realtree Hardwoods® Camo
Hunter Edition
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the code next to the part
number, and
this chart for color
verification.
PAGE 2 of 6
5TE5
Model
codes can
be used to
confirm the
model year
of the unit.
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
*Paint code for reference only - Do
not paint plastic
body.
N/A - Not Available.
^5187 is not
textured.
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.
2003 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
UTILITY (CONT’D)
Kodiak 4X4 Ultramatic
YFM4FAR
Kodiak 400 Ultramatic 2WD
YFM4AR
Big Bear 400 4X4
YFM40FR
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
5TE1
5VH1
5FUC
Model
codes can
be used to
confirm the
model year
of the unit.
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00K0
0033
00W0
00W0
0098
(PDG)
(YB)
(WVB)
(WVB)
(LGB)
5822
5135
5187^
5187^
5654
Beige
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0598
0033
00W0
00W0
0098
(DNYS1)
(YB)
(WVB)
(WVB)
(LGB)
5901
5135
5187^
5187^
5654
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00TR
0033
00W0
00W0
0098
(RTR)
(YB)
(WVB)
(WVB)
(LGB)
5650
5135
5187^
5187^
5654
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00K0
0033
00W0
00W0
0098
(PDG)
(YB)
(WVB)
(WVB)
(LGB)
5822
5135
5187^
5187^
5654
Beige
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
0598
0033
00W0
00W0
0098
(DNYS1)
(YB)
(WVB)
(WVB)
(LGB)
5901
5135
5187^
5187^
5654
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Low Gloss Black
00TR
0033
00W0
00W0
0098
(RTR)
(YB)
(WVB)
(WVB)
(LGB)
5650
5135
5187^
5187^
5654
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00K0
0033
00W0
00W0
00MA
(PDG)
(YB)
(WVB)
(WVB)
(TGM)
5822
5135
5187^
5187^
5860
Beige
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
0598
0033
00W0
00W0
00MA
(DNYS1)
(YB)
(WVB)
(WVB)
(TGM)
5901
5135
5187^
5187^
5860
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00TR
0033
00W0
00W0
00MA
(RTR)
(YB)
(WVB)
(WVB)
(TGM)
5650
5135
5187^
5187^
5860
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
*Paint code for reference only - Do
not paint plastic
body.
^5187 is not
textured.
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 3 of 6
2003 ATV Paint Reference Chart
MODEL
UTILITY (CONT’D)
Big Bear 400 2WD
YFM400NR
BearTracker
YFM250XR
MODEL
CODE
5GW9
4XEH
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00K0
0033
00W0
00W0
00MA
(PDG)
(YB)
(WVB)
(WVB)
(TGM)
5822
5135
5187^
5187^
5860
Beige
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
0598
0033
00W0
00W0
00MA
(DNS1)
(YB)
(WVB)
(WVB)
(TGM)
5901
5135
5187^
5187^
5860
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00TR
0033
00W0
00W0
00MA
(RTR)
(YB)
(WVB)
(WVB)
(TGM)
5650
5135
5187^
5187^
5860
Hunter Green
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00K0
0033
00W0
00W0
00MA
(PDG)
(YB)
(WVB)
(WVB)
(TGM)
5822
5135
5187^
5187^
5860
Beige
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
0598
0033
00W0
00W0
00MA
(DNYS1)
(YB)
(WVB)
(WVB)
(TGM)
5901
5135
5187^
5187^
5860
Red
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Chijimi Black
Chijimi Black
Titanic Gray Metallic
00TR
0033
00W0
00W0
00MA
(RTR)
(YB)
(WVB)
(WVB)
(TGM)
5650
5135
5187^
5187^
5860
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Deep Purplish Blue Metallic C
Silver
(no paint)
0583
0564
0035
(DPBSE)
(DPBMC)
(SL)
5829
5815
5616
Black /
Red
Body*
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Romantique Rouge
Silver
Silver
(no paint)
0033
00TR
0035
0035
(YB)
(RTR)
(SL)
(SL)
5135
5650
5616
5616
Black
(with Blue Flames)
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Mat Black 2
Mat Black 2
(no paint)
0033
0582
0582
(YB)
(MBL2)
(MBL2)
5135
5988
5988
Black
(with Red Flames)
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Mat Black 2
Mat Black 2
(no paint)
0033
0582
0582
(YB)
(MBL2)
(MBL2)
5135
5988
5988
SPORT
660R Raptor
YFM660RR
660R Raptor
YFM660RLER
(Limited Edition)
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
PAGE 4 of 6
5LP9
5LPC
Model
codes can
be used to
confirm the
model year
of the unit.
Team Yamaha Blue /
White
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
*Paint code for reference only - Do
not paint plastic
body.
^5187 is not
textured.
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.
2003 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
SPORT (CONT’D)
Banshee
YFZ350R
5FKJ
Team Yamaha Blue /
White
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
no paint
0583
0035
0035
(DPBSE) 5829
5616
(SL)
5616
(SL)
Black /
Red
Body*
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Romantique Rouge
Silver
Silver
no paint
0033
00TR
0035
0035
(YB)
(RTR)
(SL)
(SL)
5135
5650
5616
5616
Banshee
YFZ350LER
(Limited Edition)
5FKM
Yellow /
Black
(with Flames)
Body*
Body*
Frame
Front Bumper
Wheel
Light GreenishYellow Solid 3
Yamaha Black
Mat Black 2
Mat Black 2
no paint
0864
0033
0582
0582
(LGYS3)
(YB)
(MBL2)
(MBL2)
5812
5135
5988
5988
Wolverine 4X4
YFM35FXR
4KBV
Team Yamaha Blue
Body*
Frame
Front Bumper
Carrier (R)
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Silver
Yamaha Black
Silver
0583
0033
0035
0033
0035
(DPBSE)
(YB)
(SL)
(YB)
(SL)
5829
5135
5616
5135
5616
Black
Body*
Frame
Front Bumper
Carrier (R)
Wheel
Yamaha Black
Yamaha Black
Yamaha Black
Yamaha Black
Low Gloss Black
0033
0033
0033
0033
0098
(YB)
(YB)
(YB)
(YB)
(LGB)
5135
5135
5135
5135
5654
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
no paint
0583
0035
0035
(DPBSE) 5829
5616
(SL)
5616
(SL)
Body*
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Romantique Rouge
Silver
Silver
no paint
0033
00TR
0035
0035
(YB)
(RTR)
(SL)
(SL)
5135
5650
5616
5616
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
Silver
0583
0035
0035
0035
(DPBSE)
(SL)
(SL)
(SL)
5829
5616
5616
5616
Black /
Red
Body*
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Romantique Rouge
Silver
Silver
Silver
0033
00TR
0035
0035
0035
(YB)
(RTR)
(SL)
(SL)
(SL)
5135
5650
5616
5616
5616
Team Yamaha Blue
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Yamaha Black
Silver
0583
0033
0033
0035
(DPBSE)
(YB)
(YB)
(SL)
5829
5135
5135
5616
Hunter Green
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Yamaha Black
Silver
00K0
0033
0033
0035
(PDG)
(YB)
(YB)
(SL)
5822
5135
5135
5616
Warrior
YFM35XR
5NF8 /
5NF9
Team Yamaha Blue /
White
Black /
Red
Blaster
YFS200R
Breeze
YFA1R / C
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
5VM1
5VJ1 /
5VJ2
Model
codes can
be used to
confirm the
model year
of the unit.
Team Yamaha Blue /
White
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
*Paint code for reference only - Do
not paint plastic
body.
^5187 is not
textured.
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
2003 ATV Paint Reference Chart
MODEL
MODEL
CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
SPORT (CONT’D)
Raptor 80
YFM80WR
5TH5
Team Yamaha Blue /
White
Black /
Red
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
PAGE 6 of 6
Model codes
can be used
to confirm
the model
year of the
unit.
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
ROUTE TO:
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Silver
Silver
0583
0033
0035
0035
(DPBSE)
(YB)
(SL)
(SL)
5829
5135
5616
5616
Body*
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Romantique Rouge
Yamaha Black
Silver
Silver
0033
00TR
0033
0035
0035
(YB)
(RTR)
(YB)
(SL)
(SL)
5135
5650
5135
5616
5616
*Paint code for reference only - Do
not paint plastic
body.
^5187 is not
textured.
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.
✓ SERVICE ✓ PARTS ✓ WARRANTY ✓ SALES
© 2003 YAMAHA MOTOR CORPORATION, U.S.A.
2003 MODELS
ATV Service Literature
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 literature
part numbers will be listed, but “Same as . . .” will appear in the appropriate Manual column. The manuals 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
lists other publications related to your dealership operation (see page 3), which can be ordered from
Yamaha Parts and Accessories.
Model
Model Name
Owner’s
Manual
Service
Manual
Supplement
Assembly
Manual
LIT-11666-15-38
Same as
YFM80W P
YFM80WR
Raptor 80
LIT-11626-16-07
LIT-11616-YF-80
Same as
YFM80W D~P
LIT-11616-15-38
Same as
YFM80W P
YFA1R
Breeze
LIT-11626-16-04
LIT-11616-YF-00
Same as
YFA1 W~P
LIT-11616-15-08
Same as
YFA1 P
LIT-11666-06-75
Same as
YFA1 W~P
YFA1R(C)
Breeze (Calif.)
LIT-11626-16-04
LIT-11616-YF-00
Same as
YFA1 W~P
LIT-11616-15-08
Same as
YFA1 P
LIT-11666-06-75
Same as
YFA1 W~P
YFS200R
Blaster
LIT-11626-16-37
LIT-11616-07-20
LIT-11616-16-37
LIT-11616-15-05
Same as
YFS200 P
LIT-11666-16-37
YFM250XR
BearTracker
LIT-11626-16-14
LIT-11616-12-01
Same as
YFM250X L~P
LIT-11616-14-17
Same as
YFM250X N~P
LIT-11616-15-03
Same as
YFM250X P
LIT-11666-12-01
Same as
YFM250X L~P
YFM35FXR
Wolverine
LIT-11626-16-03
LIT-11616-FX-36
Same as
YFM35FX G~P
LIT-11616-14-02
Same as
YFM35FX N~P
LIT-11616-15-07
Same as
YFM35FX P
LIT-11666-09-58
Same as
YFM35FX G~P
YFM35XR
Warrior
LIT-11626-16-08
LIT-11616-YM-37
Same as
YFM35X A~P
LIT-11616-15-09
Same as
YFM35X P
LIT-11666-08-60
Same as
YFM35X E~P
PAGE 1 of 3
2003 ATV Service Literature
Model
Model Name
Owner’s
Manual
Service
Manual
Supplement
Assembly
Manual
YFM35XR(C)
Warrior (Calif.)
LIT-11626-16-08
LIT11616-YM-37
Same as
YFM35X A~P
LIT-11616-15-09
Same as
YFM35X P
LIT-11666-08-60
Same as
YFM35X E~P
YFZ350R
Banshee
LIT-11626-16-29
LIT-11616-YF-36
Same as
YFZ350 T~P
LIT-11616-15-04
Same as
YFZ350 P
LIT-11666-07-86
Same as
YFZ350 B~P
YFZ350LER
Banshee
Limited Edition
LIT-11626-16-29
LIT-11616-YF-36
Same as
YFZ350 T~P
LIT-11616-15-04
Same as
YFZ350 P
LIT-11666-07-86
Same as
YFZ350 B~P
YFM4AR
Kodiak 400 2WD
Ultramatic
LIT-11626-16-35
YFM400NR
LIT-11616-16-02
LIT-11616-16-35
LIT-11666-16-35
Big Bear 400 2WD LIT-11626-16-12
LIT-11616-BB-2K
Same as
YFM400 M~P
LIT-11616-15-21
Same as
YFM400 P
LIT-11666-13-34
Same as
YFM400 M~P
YFM40FR
Big Bear 4x4
LIT-11626-16-13
LIT-11616-BB-2K
Same as
YFM40F M~P
LIT-11616-15-22
Same as
YFM40F P
LIT-11666-13-22
Same as
YFM40F M~P
YFM4FAR
Kodiak 4x4
Ultramatic
LIT-11626-16-02
LIT-11616-16-02
YFM4FAHR
Kodiak 4x4
Hunter Ultramatic
LIT-11626-16-02
LIT-11616-16-02
LIT-11666-16-02
YFM45FAR
Kodiak 450 4x4
Ultramatic
LIT-11626-16-01
LIT-11616-16-01
LIT-11666-16-01
YFM45FAHR
Kodiak 450 4x4
Hunter Ultramatic
LIT-11626-16-01
LIT-11616-16-01
LIT-11666-16-01
YFM660FR
Grizzly 660
LIT-11626-16-34
LIT-11616-15-01
Same as
YFM660F P
LIT-11616-16-34
LIT-11666-15-01
Same as
YFM660F P
YFM660FRGY
Grizzly 660
Limited Edition
LIT-11626-16-34
LIT-11616-15-01
Same as
YFM660F P
LIT-11616-16-34
LIT-11666-15-01
Same as
YFM660F P
YFM66FHR
Grizzly 660 Hunter LIT-11626-16-34
LIT-11616-15-01
Same as
YFM66FH P
LIT-11616-16-34
LIT-11666-15-01
Same as
YFM66FH P
YFM660RR
660R Raptor
LIT-11626-16-09
LIT-11616-14-21
Same as
YFM660R N~ P
LIT-11616-15-31
Same as
YFM660R P
LIT-11666-14-21
Same as
YFM660R N~P
YFM660RLER
660R Raptor
Limited Edition Black
LIT-11626-16-09
LIT-11616-14-21
Same as
YFM660R N~P
LIT-11616-15-31
Same as
YFM660R P
LIT-11666-14-21
Same as
YFM660R N~P
PAGE 2 of 3
LIT-11666-16-02
2003 ATV Service Literature
Order the following publications from Yamaha Parts and Accessories:
Other Publications
ATV Warranty Statement*
ATV Safety Alert
Ride Safe, Ride Smart Videotape
ATV Rally CD-ROM
Used ATV Safety Verification Form
Y-12 Hang Tag (Badger only)
Y-6 Hang Tag
Utility Hang Tag
Sport Hang Tag (Raptor, Banshee, Warrior, Blaster)
General Hang Tag (all others)
Tips and Practice Guide for the ATV Rider
ATV Set-Up and Predelivery Checklist
2003 ATV Flat Rate Manual
ATV Technical Service Data (’99~’01)
2002 Motorcycle/ATV Service Data Book
Warranty and Y.E.S. Handbook
Parts System Handbook
2003 ATV Accessory Brochure
2003 ATV Full Line Mini Brochure
2003 Sports ATVs Brochure
2003 Utility ATVs Brochure
Y.E.S. Plan Highlights - Motorsports
Y.E.S. Sample Contract
Y.E.S. Registration Card
Y.E.S. Used Hang Tag
Y.E.S. Motorsports Hang Tag
Y.E.S. Used Unit Registration Card
Y.E.S. Motorsports Brochure
Y.E.S. Maintenance Log
Y.E.S. Request to Cancel Form
Y.E.S. Plan Lienholder Information
Y.E.S. It Works Video
Part Number
LIT-11790-02-86
LIT-17451-02-01
VID-17299-00-00
LIT-17299-CD-00
LIT-17299-01-2K
2FJ-2819R-00-00
IHN-2819R-00-00
3GH-2819R-00-00
3JM-2819R-00-00
3FA-2819R-00-00
LIT-11626-15-49
LIT-17161-01-2K
LIT-17750-00-03
LIT-17571-SD-01
LIT-SDATA-MC-AT
LIT-11760-00-02
LIT-10080-07-01
LIT-ATCAT-00-03
LIT-ATVMI-N1-03
LIT-11103-SP-OR
LIT-11103-UT-IL
LIT-11580-00-05
LIT-11580-00-38
LIT-11590-00-04
LIT-11580-00-40
LIT-11580-00-16
LIT-11580-00-19
LIT-11580-00-36
LIT-11580-00-03
LIT-11580-00-10
LIT-11580-00-08
VID-10660-00-78
*The Limited Warranty Statement is also printed in each Owner’s Manual.
ROUTE TO:
✓ SERVICE ✓ PARTS ✓ WARRANTY ✓ SALES
PAGE 3 of 3
© 2003 YAMAHA MOTOR CORPORATION, U.S.A.
2003 MODELS
ATV Primary ID Numbers
The following is a comprehensive listing of Primary ID numbers for 2003 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 microfiche or CD-ROM.
Model
Model Name
YFM80WR
Raptor 80
YFA-1R
Displacement
79cc
Breeze
124cc
Model Code
5TH5
5VJ1
Starting PID No.*
AB02Y-009110
AE013-011538
YFA-1RC
Breeze (California Model)
124cc
5VJ2
AE01Y-001876
YFM25XR
BearTracker
230cc
4XEH
AG01Y-091201
YFS200R
Blaster
YFZ350R
Banshee
YFZ350LER
YFM35FXR
347cc
5VM1
5FKJ
Banshee Special Edition
347cc
5FKM
Warrior
348cc
5NF8
Wolverine 4WD
YFM35XR
195cc
348cc
4KBV
YFM35XRC
Warrior (California Model)
348cc
5NF9
YFM40FR
Big Bear 400 4WD
386cc
5FUC
YFM40NR
Big Bear 400 2WD
386cc
AH04Y-011627
3GD03-031103
AH01Y-005632
AH08Y-000101
AH06Y-034801
Kodiak 400 2WD
YFM4FHAR
Kodiak 400 Hunter Edition
401cc
5TE5
AJ09Y-000101
YFM45FAHR
Kodiak 450 Hunter Edition
421cc
5ND5
AJ10Y-000101
660R Raptor Limited Edition
660cc
5LPC
AM01Y-027578
Grizzly 660 Hardwoods Hunter Edition
660cc
5KM8
AM03Y-000101
660cc
5KMG
AM03Y-016697
Kodiak 400 4WD
YFM45FAR
YFM660RR
YFM660RLER
YFM660FR
YFM660FHR
YFM660FRGY
YFM66FHRWL
Kodiak 450
660R Raptor
Grizzly 660
Grizzly 660 Limited Edition
Grizzly Wetlands Hunter Edition
401cc
421cc
660cc
660cc
660cc
5VH1
3GG03-038806
3GG03-040522
YFM4AR
YFM4FAR
401cc
5GW9
AG023-000010
5TE1
5ND1
5LP9
5KMA
5KMD
AJ08Y-000101
AJ07Y-000101
AJ06Y-000101
AM01Y-022872
AM03Y-000127
AM03Y-006985
* The Serial Number of the ATV is the last 6-digits of the VIN. When using the YDS (Yamaha Dealer System), you are required
to 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 type
in 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 a
7-digit serial number with a zero in the first position.
ROUTE TO:
✓ SERVICE ✓ PARTS ✓ WARRANTY ✓ SALES
PAGE 1 of 1
© 2001 YAMAHA MOTOR CORPORATION, U.S.A.
2002 MODELS
ATV Paint Reference Chart
This bulletin provides paint identification and ordering information for all 2002-model ATVs. All ATV paint
may be ordered through Color Rite:
Color Rite Distribution Company
11603 Groveland Ave.
Whittier, CA 90604
For Info (562) 947-9796
Fax (562) 947-5087
To ORDER, CALL: (800) 736-7980
E-Mail: colorritebh@earthlink.com
Web Site: www.color-rite.com.
When ordering, please provide Color Rite with the Year, Model, and Paint Code. Remember to provide
call back information for your dealership (e.g. phone number / fax / e-mail).
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)
A Model Application Guide providing detailed information by model year can be found at 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 parts
from the parts catalog. Paint codes are generally listed on the first page of the parts catalog and next to
the part number of the pre-painted or plastic body part. This chart can be used to confirm the color of
the part you are ordering. The Model Code and starting V.I.N. numbers are also listed on the first page
of the parts catalog and can be used to confirm the model year of the ATV. The Sales color name may
be used for more than one paint color. Applicable Sales Color Codes have also been included in the
Sales Color Name column.
PAGE 1 of 5
2002 ATV Paint Reference Chart
MODEL
MODEL CODE
SALES
COLOR NAME
COMPONENT
PAINT
COLOR NAME
"Grizzly 660 4X4"
(Hunter Edition)
YFM660FHP
5KM5
Hunter Edition
Body*
(RealTree Hardwoods®) Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Low Gloss Black
Chijimi Black
Low Gloss Black
"Grizzly 660 4X4"
YFM660FP
5KM1
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Beige (E)
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
0033
0098
00W0
0098
(YB)
(LGB)
(WVB)
(LGB)
5135
5654
5187^
5654
Pastel Deep Green
Yamaha Black
Yamaha Black
Chijimi Black
(no paint)
00K0
0033
0033
00W0
(PDG)
(YB)
(YB)
(WVB)
5822
5135
5135
5187^
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Yamaha Black
Chijimi Black
(no paint)
0598
0033
0033
00W0
(DNYS1)
(YB)
(YB)
(WVB)
5901
5135
5135
5187^
Red (R)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Yamaha Black
Chijimi Black
(no paint)
00TR
0033
0033
00W0
(RTR)
(YB)
(YB)
(WVB)
5650
5135
5135
5187^
Body
Frame
Front Bumper
Carrier (F&R)
Wheel
Light Gray Metallic B
Yamaha Black
Yamaha Black
Chijimi Black
(no paint)
0698
0033
0033
00W0
(LNMB)
(YB)
(YB)
(WVB)
5183
5135
5135
5187^
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Deep Purplish Blue Metallic C
Silver
(no paint)
0583
0564
0035
(DPBSE) 5829
(DPBMC) 5815
(SL)
5616
Body*
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Radical White
Silver
Silver
(no paint)
0033
00UJ
0035
0035
(YB)
(RW)
(SL)
(SL)
5135
5457
5616
5616
"Grizzly 660 4X4"
YFM660FPS
5KM6
Limited Edition Silver
“660R Raptor"
YFM660RP
5LP5
Team Yamaha Blue /
White (L)
Black /
White (W)
"Kodiak 4X4"
(Hunter Edition)
YFM4FAHP
5GHR
Hunter Edition
Body*
(RealTree Hardwoods®) Frame
Front Bumper
Carrier (F&R)
Wheel
N/A
Yamaha Black
Low Gloss Black
Low Gloss Black
Low Gloss Black
0033
0098
0098
0098
(YB)
(LGB)
(LGB)
(LGB)
5135
5654
5654
5654
"Kodiak 4X4"
YFM4FAP
5GHK
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00K0
0033
00MA
0033
00MA
(PDG)
(YB)
(TGM)
(YB)
(TGM)
5822
5135
5860
5135
5860
Beige (E)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
0598
0033
00MA
0033
00MA
(DNYS1)
(YB)
(TGM)
(YB)
(TGM)
5901
5135
5860
5135
5860
Red (R)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00TR
0033
00MA
0033
00MA
(RTR)
(YB)
(TGM)
(YB)
(TGM)
5650
5135
5860
5135
5860
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
The Model Code and
VIN numbers are also
listed on the first page of
the Parts Catalog and
can be used to confirm
the model year of the
ATV.
PAGE 2 of 5
Model codes
can be used to
confirm the
model year of
the unit.
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
The letter in parenthesis is the Sales
Color Code e.g., (L)
*Paint code for reference only - Do
not paint plastic
body (except
Grizzly 660 4x4
Limited Edition
Silver).
NOTE: Stripes are
available as graphic sets.
N/A - Not Available.
^ is not textured.
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.
2002 ATV Paint Reference Chart
MODEL
"Big Bear 400 4X4"
(Hunter Edition)
YFM40FHP
"Big Bear 400 4X4"
YFM40FP
SALES
MODEL CODE
COLOR NAME
COMPONENT
5FUA
Hunter Edition
Body*
(RealTree X-tra® Brown Frame
Camo Seat)
Front Bumper
Carrier (F&R)
Wheel
PAINT
COLOR NAME
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
YAMAHA
PAINT CODE
00K0
(PDG)
0033
(YB)
00MA (TGM)
0033
(YB)
00MA (TGM)
COLOR RITE
PAINT CODE
5FUA
5822
5135
5860
5135
5860
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00K0
0033
00MA
0033
00MA
(PDG)
(YB)
(TGM)
(YB)
(TGM)
5822
5135
5860
5135
5860
Beige (E)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
0598
0033
00MA
0033
00MA
(DNYS1)
(YB)
(TGM)
(YB)
(TGM)
5901
5135
5860
5135
5860
Red (R)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00TR
0033
00MA
0033
00MA
(RTR)
(YB
(TGM)
(YB)
(TGM)
5650
5135
5860
5135
5860
"Big Bear 400"
(2WD)
(Hunter Edition )
YFM40HP
5GW7
Hunter Edition
Body*
(RealTree X-tra® Brown Frame
Camo Seat)
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00K0
0033
00MA
0033
00MA
(PDG)
(YB)
(TGM)
(YB)
(TGM)
5822
5135
5860
5135
5860
"Big Bear 400"
(2WD)
YFM40P
5GW7
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00K0
0033
00MA
0033
00MA
(PDG)
(YB)
(TGM)
(YB)
(TGM)
5822
5135
5860
5135
5860
Beige (E)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
0598
0033
00MA
0033
00MA
(DNYS1)
(YB)
(TGM)
(YB)
(TGM)
5901
5135
5860
5135
5860
Red (R)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00TR
0033
00MA
0033
00MA
(RTR)
(YB)
(TGM)
(YB)
(TGM)
5650
5135
5860
5135
5860
Team Yamaha Blue (L)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Silver
Yamaha Black
Silver
0583
0033
0035
0033
0035
(DPBSE)
(YB)
(SL)
(YB)
(SL)
5829
5135
5616
5135
5616
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00K0
0033
00MA
0033
00MA
(PDG)
(YB)
(TGM)
(YB)
(TGM)
5822
5135
5860
5135
5860
"Wolverine 4X4"
YFM35FXP
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
4KBR
Model codes
can be used to
confirm the
model year of
the unit.
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
The letter in parenthesis is the Sales
Color Code e.g., (L)
*Paint code for reference only - Do
not paint plastic
body.
NOTE: Stripes are
available as graphic sets.
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.
The Model Code and
VIN numbers are also
listed on the first page of
the Parts Catalog and
can be used to confirm
the model year of the
ATV.
PAGE 3 of 5
2002 ATV Paint Reference Chart
MODEL
"Warrior"
YFM350XP
YFM35XPC
MODEL CODE
5NF4
5NF5
SALES
COLOR NAME
Team Yamaha Blue /
White (L)
Black /
White (B)
"Banshee"
YFZ350P
5FKE
Team Yamaha Blue /
White (L)
Black /
White (B)
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
no paint
0583
0035
0035
(DPBSE)
(SL)
(SL)
5829
5616
5616
Body*
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Radical White
Silver
Silver
no paint
0033
00UJ
0035
0035
(YB)
(RW)
(SL)
(SL)
5135
5457
5616
5616
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
no paint
0583
0035
0035
(DPBSE)
(SL)
(SL)
5829
5616
5616
Body*
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Radical White
Silver
Silver
no paint
0033
00UJ
0035
0035
(YB)
(RW)
(SL)
(SL)
5135
5457
5616
5616
"BearTracker"
YFM25XHP
4XEE
Hunter Edition
Body*
(RealTree X-tra® Brown Frame
Camo Seat)
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00K0
0033
00MA
0033
00MA
(PDG)
(YB)
(TGM)
(YB)
(TGM)
5822
5135
5860
5135
5860
"BearTracker"
YFM25XP
4XEE
Hunter Green (GR)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00K0
0033
00MA
0033
00MA
(PDG)
(YB)
(TGM)
(YB)
(TGM)
5822
5135
5860
5135
5860
Beige (E)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
0598
0033
00MA
0033
00MA
(DNYS1)
(YB)
(TGM)
(YB)
(TGM)
5901
5135
5860
5135
5860
Red (R)
Body*
Frame
Front Bumper
Carrier (F&R)
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Yamaha Black
Titanic Gray Metallic
00TR
0033
00MA
0033
00MA
(RTR)
(YB)
(TGM)
(YB)
(TGM)
5650
5135
5860
5135
5860
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
Silver
0583
0035
0035
0035
(DPBSE)
(SL)
(SL)
(SL)
5829
5616
5616
5616
Body*
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Radical White
Silver
Silver
Silver
0033
00UJ
0035
0035
0035
(YB)
(RW)
(SL)
(SL)
(SL)
5135
5457
5616
5616
5616
"Blaster"
YFS200P
5KJ7
Team Yamaha Blue /
White (L)
Black /
White (B)
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
The Model Code and
VIN numbers are also
listed on the first page of
the Parts Catalog and
can be used to confirm
the model year of the
ATV.
PAGE 4 of 5
Model codes
can be used to
confirm the
model year of
the unit.
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
The letter in parenthesis is the Sales
Color Code e.g., (L)
*Paint code for reference only - Do
not paint plastic
body.
NOTE: Stripes are
available as graphic sets.
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.
2002 ATV Paint Reference Chart
MODEL
MODEL CODE
SALES
COLOR NAME
“Breeze”
YFA1P / C
3FAW / 3FAX
Black /
White
“Raptor 80”
YFM80RPL
5TH1
Team Yamaha Blue /
White
C - Designates
California Model
Model codes
can be used to
confirm the
model year of
the unit.
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
The Sales Color
Name is for unit
color identification
and may be used
for more than one
paint color.
The letter in parenthesis is the Sales
Color Code e.g., (L)
COMPONENT
PAINT
COLOR NAME
YAMAHA
PAINT CODE
COLOR RITE
PAINT CODE
Body*
Body*
Frame
Front Bumper
Wheel
Yamaha Black
Radical White
Yamaha Black
Yamaha Black
Silver
0033
00UJ
0033
0033
0035
(YB)
(RW)
(YB)
(YB)
(SL)
5135
5457
5135
5135
5616
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Silver
Silver
0583
0033
0035
0035
(DPBSE)
(YB)
(SL)
(SL)
5829
5135
5616
5616
*Paint code for reference only - Do
not paint plastic
body.
NOTE: Stripes are
available as graphic sets.
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.
The Model Code and
VIN numbers are also
listed on the first page of
the Parts Catalog and
can be used to confirm
the model year of the
ATV.
ROUTE TO:
✓ SERVICE ✓ PARTS ✓ WARRANTY ✓ SALES
PAGE 5 of 5
© 2002 YAMAHA MOTOR CORPORATION, U.S.A.
2002 MODELS
ATV Service Literature
Effective 6/25/02 this Technical Bulletin replaces AT2002-0008; please remove and destroy AT2002-008.
Denotes a change in the original Technical Bulletin.
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 literature
part numbers will be listed, but “Same as . . .” will appear in the appropriate Manual column. The manuals 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 lists
other publications related to your dealership operation (see page 2), which can be ordered from Yamaha
Parts and Accessories.
Model
Model Name
Owner’s
Manual
Service
Manual
Supplement
Assembly
Manual
LIT-11666-15-38
YFM80WP
Raptor 80
LIT-11626-15-38
LIT-11616-YF-80
LIT-11616-15-38
YFA1P
Breeze
LIT-11626-15-08
LIT-11616-YF-00
Same as
YFA1 W~N
LIT-11616-15-08
YFA1P(C)
Breeze (Calif.)
LIT-11626-15-08
LIT-11616-YF-00
Same as
YFA1 W~N
LIT-11616-15-08
LIT-11666-06-75
Same as
YFA1 W~N
YFS200P
Blaster
LIT-11626-15-05
LIT-11616-07-20
Same as
YFS200 U~N
LIT-11616-15-05
LIT-11666-07-20
Same as
YFS200 A~N
YFM250XP
BearTracker
LIT-11626-15-03
LIT-11616-12-01
Same as
YFM250X L~N
LIT-11616-15-03
LIT-11616-14-17
LIT-11666-12-01
Same as
YFM250X L~N
YFM350FXP
Wolverine
LIT-11626-15-07
LIT-11616-FX-36
Same as
YFM350FX G~N
LIT-11616-15-07
LIT-11666-09-58
Same as
YFM350FX G~N
YFM350XP
Warrior
LIT-11626-15-09
LIT-11616-YM-37
Same as
YFM350X A~N
LIT-11616-15-09
LIT-11666-08-60
Same as
YFM350X E~N
YFM350XP(C)
Warrior (Calif.)
LIT-11626-15-09
LIT11616-YM-37
Same as
YFM350X A~N
LIT-11616-15-09
LIT-11666-08-60
Same as
YFM350X E~N
YFZ350P
Banshee
LIT-11626-15-04
LIT-11616-YF-36
Same as
YFZ350 T~N
LIT-11616-15-04
LIT-11666-07-86
same as
YFZ350 B~N
LIT-11666-06-75
Same as
YFA1 W~N
PAGE 1 of 2
2002 ATV Service Literature
Model
Owner’s
Manual
Model Name
Service
Manual
Supplement
Assembly
Manual
YFM400P
Big Bear 2WD
LIT-11626-15-21
LIT-11616-BB-2K
Same as
YFM400 M~N
LIT-11616-15-21
LIT-11666-13-34
Same as
YFM400 M~N
YFM400FP
Big Bear 4WD
LIT-11626-15-22
LIT-11616-BB-2K
Same as
YFM400FW M~N
LIT-11616-15-22
LIT-11666-13-22
Same as
YFM400FW M~N
YFM400FAP
Kodiak 4WD
LIT-11626-15-19
LIT-11616-KD-2K
Same as
YFM400FWA M~N
LIT-11616-15-19
LIT-11666-13-21
Same as
YFM400FWA M~N
YFM400FHAP
Kodiak 4WD
Hunter
LIT-11626-15-19
LIT-11616-KD-2K
Same aa
YFM400FWHA M~N
LIT-11616-15-19
LIT-11666-13-21
Same as
YFM400FWHA M~N
YFM660FAP
Grizzly 660
LIT-11626-15-01
LIT-11616-15-01
YFM660FSAP
Grizzly 660 Silver
LIT-11626-15-01
LIT-11616-15-01
LIT-11616-14-21
Same as
YFM660R N
LIT-11616-15-31
LIT-11666-14-21
Same as
YFM660R N
660R Raptor
Limited Edition Black
LIT-11626-15-31
LIT-11616-14-21
Same as
YFM660R N
LIT-11616-15-31
LIT-11666-14-21
Same as
YFM660R N
YFM660FHAP
YFM660RP
YFM660RP-B
Grizzly 660 Hunter LIT-11626-15-01
660R Raptor
LIT-11626-15-31
LIT-11666-15-01
LIT-11616-15-01
LIT-11666-15-01
LIT-11666-15-01
Order the following publications from Yamaha Parts and Accessories:
Other Publications
Part Number
ATV Warranty Statement*
ATV Safety Alert
Ride Safe, Ride Smart Videotape
ATV Rally CD-ROM
Used ATV Safety Verification Form
Y-12 Hang Tag (Badger only)
Sport Hang Tag (Raptor, Banshee, Warrior, Blaster)
General Hang Tag (all others)
Tips and Practice Guide for the ATV Rider
ATV Set-Up and Predelivery Checklist
2002 ATV Flat Rate Manual
ATV Technical Service Data (’99~’01)
Motorcycle/ATV Service Data Binder
Y.E.S. Plan Highlights
Y.E.S. Sample Contract
Warranty and Y.E.S. Handbook
Parts System Handbook
2002 ATV Accessory Brochure
2002 ATV Full Line Mini Brochure
2002 Sports ATVs Brochure
2002 Utility ATVs Brochure
LIT-11790-02-86
LIT-17451-01-01
VID-17299-00-00
LIT-17299-CD-00
LIT-17299-01-2K
2FJ-2819R-00-00
3JM-2819R-00-00
3FA-2819R-00-00
LIT-11626-15-49
LIT-17161-01-2K
LIT-17750-00-02
LIT-17571-SD-01
LIT-SDATA-MC-AT
LIT-11580-00-05
LIT-11580-00-27
LIT-11760-00-02
LIT-10080-07-01
LIT-ATCAT-00-02
LIT-ATVMI-N1-02
LIT-11102-SP-OR
LIT-11102-UT-IL
*The Limited Warranty Statement is also printed in each Owner’s Manual.
PAGE 2 of 2
ROUTE TO:
✓ SERVICE ✓ PARTS ✓ WARRANTY ✓ SALES
© 2002 YAMAHA MOTOR CORPORATION, U.S.A.
2002 MODELS
ATV Primary ID Numbers
The following is a comprehensive listing of Primary ID numbers for 2002 Yamaha ATV’s. 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 microfiche or CD-ROM.
Model
Model Name
YFM80WP
Raptor 80
5TH1
Breeze (California Model)
124cc
3FAX
AE01Y-001326
BearTracker
230cc
4XEE
AG01Y-072601
Breeze
YFS200P
Blaster
YFM25XP
YFM25XHP
BearTracker Hunter Edition
YFZ350P
YFM35FXP
124cc
195cc
230cc
3FAW
5KJ7
4XEE
Banshee
347cc
5FKE
Warrior
348cc
5NF4
Wolverine
YFM35XP
Starting PID No.*
79cc
YFA-1P
YFA-1PC
Displacement Model Code
348cc
4KBR
AB02Y-000032
AE013-007350
3JM03-039885
AG01Y-075350
3GG03-028762
AH04Y-009652
3GD03-018702
YFM350XPC
Warrior (California Model)
348cc
5NF5
AH01Y-004072
YFM40HP
Big Bear 2WD Hunter Edition
386cc
5GW7
AH08Y-019549
386cc
5FUA
AH06Y-020101
401cc
5GH R
AJ03Y-027392
YFM40P
YFM40FP
YFM40FHP
Big Bear 2WD
Big Bear 4WD
386cc
Kodiak 4WD
401cc
660R Raptor
660cc
Big Bear 4WD Hunter Edition
YFM4FAP
YFM4FHAP
Kodiak Hunter Edition
YFM660RP
YFM660RPB
YFM660FP
YFM660FHP
YFM660FPS
386cc
5GW7
5FUA
5GH K
5LP5
AH08Y-017702
AH06Y-016201
AJ03Y-026912
AM01Y-003061
660R Black Raptor
660cc
5LP8
AM01-015340
Grizzly 660 Hunter Edition
660cc
5KM5
AM02Y-002030
Grizzly 660
Grizzly 660 Limited Edition Silver
660cc
660cc
5KM1
5KM6
AM02Y-000030
AM02Y-010957
* 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 (the
Yamaha 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 matter what other characters are in the VIN. So if the correct Primary ID is 3GG03-000353, you would type in 3GG030000353 on
YDS (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 a
7-digit serial number with a zero in the first position.
ROUTE TO:
✓ SERVICE ✓ PARTS ✓ WARRANTY ✓ SALES
PAGE 1 of 1
© 2001 YAMAHA MOTOR CORPORATION, U.S.A.
2001 MODELS
ATV Paint Reference Chart
This bulletin provides paint identification and ordering information for 2001-model ATVs. All ATV paint
may be ordered through Color Rite:
National Sales Office
11603 Groveland Ave.
Whittier, CA 90604
For Info (562) 947-9796
Fax (562) 947-5087
To ORDER, CALL (800) 736-7980
or
E-Mail: colorritebh@earthlink.com
When ordering, please provide Color Rite with the Year, Model, and Paint Code, and provide call-back
information 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 information, by model year, can also be found on Color Rite’s web page: www.color-rite.com.
PAGE 1 of 5
2001 ATV Paint Reference Chart
Model
YFM660RN/C
(Raptor)
Model
Code
5LP1 / 5LP3
ATV Color
Name
Team Yamaha Blue /
White (L)
Black / White (W)
YFM600FAHN
(Grizzly 4X4)
5GTK
YFM600FAN
(Grizzly 4X4)
5GTE
Hunter Edition
(Realtree® X-tra™)
Hunter Green (GR)
Beige (E)
Red (R)
YFM400AN
(Kodiak 2WD)
5HA7
Hunter Green (GR)
Beige (E)
Red (R)
YFM400FAHN
(Kodiak 4X4)
5GHF
(C) Designates
California model
Hunter Edition
(Realtree® X-tra™)
ATV Color Name
is for unit color
identification.
NOTE:
When ordering pre-painted parts from the parts catalog, check the first
page of the parts list (microfiche or CD-ROM), the code next to the part,
and this chart for color verification.
PAGE 2 of 5
Component
Paint Color
Name
Yamaha Paint Color-Rite Paint
Code
Code
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Deep Purplish Blue Metallic C
Silver
(No Paint)
0583 (DPBSE) 5829U
0564 (DPBMC) 5815U
5616U
0035 (SL)
Body*
Frame
Front Bumper
Wheel
Radical White
Silver
Silver
(No Paint)
00UJ (RW)
0035 (SL)
0035 (SL)
5457UL
5616U
5616U
Body*
Frame
Front Bumper
Wheel
N/A
Yamaha Black
Low Gloss Black
Low Gloss Black
N/A
0033 (YB)
0098 (LGB)
0098 (LGB)
N/A
5135UL
5654U
5654U
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033 (YB)
00MA (TGM)
00MA (TGM)
5822U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
0598 (DNYS1)
0033 (YB)
00MA (TGM)
00MA (TGM)
5901U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00TR (RTR)
0033 (YB)
00MA (TGM)
00MA (TGM)
5650U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033 (YB)
00MA (TGM)
00MA (TGM)
5822U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
0598 (DNYS1)
0033 (YB)
00MA (TGM)
00MA (TGM)
5901U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00TR (RTR)
0033 (YB)
00MA (TGM)
00MA (TGM)
5650U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
N/A
Yamaha Black
Low Gloss Black
Low Gloss Black
N/A
0033 (YB)
0098 (LGB)
0098 (LGB)
N/A
5135UL
5654U
5654U
* Paint code for
reference only - Do
not paint plastic
body.
Color-Rite paint code information:
U = Urethane
L = Lacquer
UL = Urethane or Lacquer
1000 series codes are base coats
5000 series codes are color coats
All color coats must be clear coated
^ Paint is in the
process of
being
formulated Contact ColorRite for base
coat information.
2001 ATV Paint Reference Chart
Model
YFM400FAN
(Kodiak 4X4)
Model
Code
5GH9
ATV Color
Name
Hunter Green (GR)
Beige (E)
Red (R)
YFM400FHN
(Big Bear 4X4
w/ Camo Seat)
5FU9
Hunter Green
(Realtree® X-tra™ Seat)
YFM400FN
(Big Bear 4X4)
5FU6
Hunter Green (GR)
Beige (E)
Red (R)
YFM400HN
(Big Bear 2WD
w/ Camo Seat)
5GW4
YFM400N
5GW4
(Big Bear 2WD)
Hunter Green
(Realtree® X-tra™ Seat)
Hunter Green (GR)
Beige (E)
Red (R)
(C) Designates
California model
Component
Paint Color
Name
Yamaha Paint Color-Rite Paint
Code
Code
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033 (YB)
00MA (TGM)
00MA (TGM)
5822U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
0598 (DNYS1)
0033 (YB)
00MA (TGM)
00MA (TGM)
5901U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00TR (RTR)
0033 (YB)
00MA (TGM)
00MA (TGM)
5650U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033 (YB)
00MA (TGM)
00MA (TGM)
5822U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033 (YB)
00MA (TGM)
00MA (TGM)
5822U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
0598 (DNYS1)
0033 (YB)
00MA (TGM)
00MA (TGM)
5901U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00TR (RTR)
0033 (YB)
00MA (TGM)
00MA (TGM)
5650U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033 (YB)
00MA (TGM)
00MA (TGM)
5822U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033 (YB)
00MA (TGM)
00MA (TGM)
5822U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
0598 (DNYS1)
0033 (YB)
00MA (TGM)
00MA (TGM)
5901U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00TR (RTR)
0033 (YB)
00MA (TGM)
00MA (TGM)
5650U
5135UL
5860U
5860U
ATV Color Name
is for unit color
identification.
NOTE:
When ordering pre-painted parts from the parts catalog, check the first
page of the parts list (microfiche or CD-ROM), the code next to the part,
and this chart for color verification.
* Paint code for
reference only - Do
not paint plastic
body.
Color-Rite paint code information:
U = Urethane
L = Lacquer
UL = Urethane or Lacquer
1000 series codes are base coats
5000 series codes are color coats
All color coats must be clear coated
^ Paint is in the
process of
being
formulated Contact ColorRite for base
coat information.
PAGE 3 of 5
2001 ATV Paint Reference Chart
Model
YFM350FXN
4KBM
(Wolverine 4X4)
Model
Code
ATV Color
Name
Team Yamaha Blue /
White (L)
Hunter Green (GR)
YFZ350N
(Banshee)
5FKA
Team Yamaha Blue /
White (L)
Black / White (W)
YFM350XN/C
(Warrior)
3GDY / 5FN1
Team Yamaha Blue /
White (L)
Black / White (W)
YFM250XHN
4XEA
(BearTracker
w/ Camo Seat)
Hunter Green
(w/ Realtree® X-tra™ Seat)
YFM250XN
(BearTracker)
Hunter Green (GR)
4XEA
Beige (E)
Red (R)
YFS200N
(Blaster)
5KJ4
Team Yamaha Blue /
White (L)
Black / White (W)
(C) Designates
California model
Component
Yamaha Paint Color-Rite Paint
Code
Code
Deep Purplish Blue Solid E
Yamaha Black
Silver
Silver
0583
0033
0035
0035
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033 (YB)
00MA (TGM)
00MA (TGM)
5822U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
0035 (SL) 5616U
(no paint)
0583 (DPBSE)
0035 (SL)
5829U
5616U
Body*
Frame
Front Bumper
Wheel
Radical White
Silver
Silver
(no paint)
00UJ (RW)
0035 (SL)
0035 (SL)
5457UL
5616U
5616U
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
(no paint)
0583 (DPBSE)
0035 (SL)
0035 (SL)
5829U
5616U
5616U
Body*
Frame
Front Bumper
Wheel
Radical White
Silver
Silver
(no paint)
00UJ (RW)
0035 (SL)
0035 (SL)
5457UL
5616U
5616U
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 5822U
(PDG)
5135UL
0033 (YB)
5860U
00MA (TGM)
5860U
00MA (TGM)
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033 (YB)
00MA (TGM)
00MA (TGM)
5822U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
0598 (DNYS1)
0033 (YB)
00MA (TGM)
00MA (TGM)
5901U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00TR (RTR)
0033 (YB)
00MA (TGM)
00MA (TGM)
5650U
5135UL
5860U
5860U
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
Silver
0583
0035
0035
0035
5829U
5616U
5616U
5616U
Body*
Frame
Front Bumper
Wheel
Radical White
Silver
Silver
Silver
00UJ (RW)
0035 (SL)
0035 (SL)
0035 (SL)
ATV Color Name
is for unit color
identification.
(DPBSE)
(YB)
(SL)
(SL)
5829U
5135UL
5616U
5616U
Body*
Frame
Front Bumper
Wheel
NOTE:
When ordering pre-painted parts from the parts catalog, check the first
page of the parts list (microfiche or CD-ROM), the code next to the part,
and this chart for color verification.
PAGE 4 of 5
Paint Color
Name
(DPBSE)
(SL)
(SL)
(SL)
* Paint code for
reference only - Do
not paint plastic
body.
Color-Rite paint code information:
U = Urethane
L = Lacquer
UL = Urethane or Lacquer
1000 series codes are base coats
5000 series codes are color coats
All color coats must be clear coated
5457UL
5616U
5616U
5616U
^ Paint is in the
process of
being
formulated Contact ColorRite for base
coat information.
2001 ATV Paint Reference Chart
Model
Model
Code
ATV Color
Name
YFA1N/C
(Breeze)
3FAT / 3FAU
Black / White (W)
YFM80HN
(Badger
w/ Camo Seat)
4EMX
Hunter Green
(Realtree® X-tra™ Seat)
YFM80N/C
(Badger)
4EMX / 4EMY
Team Yamaha Blue /
White (L)
(C) Designates
California model
Component
Yamaha Paint Color-Rite Paint
Code
Code
Body*
Frame
Front Bumper
Wheel
Radical White
Yamaha Black
Yamaha Black
Silver
00UJ (RW)
0033 (YB)
0033 (YB)
0035 (SL)
5457UL
5135UL
5135UL
5616U
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Yamaha Black
Yamaha Black
00K0 (PDG)
0033 (YB)
0033 (YB)
0033 (YB)
5822U
5135UL
5135UL
5135UL
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Yamaha Black
Silver
0583
0033
0033
0035
5829U
5135UL
5135UL
5616U
ATV Color Name
is for unit color
identification.
NOTE:
When ordering pre-painted parts from the parts catalog, check the first
page of the parts list (microfiche or CD-ROM), the code next to the part,
and this chart for color verification.
ROUTE TO:
Paint Color
Name
(DPBSE)
(YB)
(YB)
(SL)
* Paint code for
reference only - Do
not paint plastic
body.
Color-Rite paint code information:
U = Urethane
L = Lacquer
UL = Urethane or Lacquer
1000 series codes are base coats
5000 series codes are color coats
All color coats must be clear coated
 SERVICE  PARTS  WARRANTY  SALES
^ Paint is in the
process of
being
formulated Contact ColorRite for base
coat information.
PAGE 5 of 5
2001 MODELS
ATV SERVICE LITERATURE
The following is a comprehensive listing of service literature part numbers for 2001 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.
These manuals may be ordered from Crestec Los Angeles, Inc. (ph: 1-888-530-9446). Refer to
Technical Bulletin AT2000-005 for more information.
Model
Actual
Displacement
Owner’s
Manual
Assembly
Manual
Service
Manual
“Badger”
YFM80N
79
LIT-11626-14-04
LIT-11666-08-19
Same as
YFM80 D~M
LIT-11616-YF-80
Same as
YFM80 D~M
“Badger Realtree
Hunter”
YFM80HN
79
LIT-11626-14-04
LIT-11666-08-19
Same as
YFM80 D~M
LIT-11616-YF-80
Same as
YFM80 D~M
“Badger” (Calif.)
YFM80N(C)
79
LIT-11626-14-04
LIT-11666-08-19
Same as
YFM80 D~M
LIT-11616-YF-80
Same as
YFM80 D~M
“Breeze”
YFA1N
124
LIT-11626-14-03
LIT-11666-06-75
Same as
YFA1 W~M
LIT-11616-YF-00
Same as
YFA1M
“Breeze” (Calif.)
YFA1N(C)
124
LIT-11626-14-03
LIT-11666-06-75
Same as
YFA1W C~M(C)
“Blaster”
YFS200N
195
LIT-11626-14-09
LIT-11666-07-20
Same as
YFS200 A~M
LIT-11616-07-20
Same as
YFS200 U~M
“Bear Tracker”
YFM250XN
229.6
LIT-11626-14-17
LIT-11666-12-01
Same as
YFM250X L~M
LIT-11616-12-01
LIT-11616-14-17
(Supplement)
Same as
YFM250X L~M
LIT-11616-YF-00
Same as
YFA1M(C)
PAGE 1 of 3
2001 ATV Service Literature
Actual
Displacement
Owner’s
Manual
229.6
LIT-11626-14-17
LIT-11666-12-01
Same as
YFM250X L~M
LIT-11616-12-01
LIT-11616-14-17
(Supplement)
Same as
YFM250X L~M
“Wolverine”
YFM350FXN
348
LIT-11626-14-02
LIT-11666-09-58
Same as
YFM350FX E~M
LIT-11616-FX-36
Same as
YFM350FX G~M
“Warrior”
YFM350XN
348
LIT-11626-14-10
LIT-11666-08-60
Same as
YFM350X E~M
LIT-11616-YM-37
Same as
YFM350X A~M
348
LIT-11626-14-10
LIT-11666-08-60
Same as
YFM350X E~MC
LIT-11616-YM-37
Same as
YFM350X A~M
347
LIT-11626-14-08
LIT-11666-07-86
Same as
YFZ350 B~M
LIT-11616-YF-36
Same as
YFZ350 T~M
“Big Bear” 2WD
YFM400N
386
LIT-11626-14--22
LIT-11666-13-34
Same as
YFM400NM
LIT-11616-BB-2K
Same as
YFM400FWNM
“Big Bear 2WD
Realtree Hunter”
YFM400HN
386
LIT-11626-14--22
“Big Bear” 4WD
YFM400FN
386
LIT-11626-14-11
LIT-11666-13-22
Same as
YFM400FWNM
LIT-11616-BB-2K
Same as
YFM400FWNM
“Big Bear - 4WD
Realtree Hunter “
YFM400FHN
386
LIT-11626-14-11
LIT-11666-13-22
Same as
YFM400FWNM
LIT-11616-BB-2K
Same as
YFM400FWNM
“Kodiak” 2WD
YFM400AN
386
LIT-11626-14-07
LIT-11666-13-39
Same as
YFM400AM
LIT-11616-KD-2K
“Kodiak - 4WD”
YFM400FAN
386
LIT-11626-14-05
LIT-11666-13-21
Same as
YFM400FAM
LIT-11616-13-21
Same as
YFM400FAM
“Kodiak - 4WD
Realtree Hunter”
YFM400FAHN
386
LIT-11626-14-05
LIT-11666-13-21
Same as
YFM400FAHM
LIT-11616-13-21
Same as
YFM400FAHM
595
LIT-11626-14-06
LIT-11666-11-21
LIT-11616-FW-00
Same as
YFM600FWAM
595
LIT-11626-14-06
LIT-11666-11-21
“Raptor”
YFM660RN
660
LIT-11626-14-21
LIT-11666-14-21
LIT-11616-14-21
“Raptor” (Calif.)
YFM660RNC
660
LIT-11626-14-21
LIT-11666-14-21
LIT-11616-14-21
Model
“Bear Tracker
Realtree Hunter”
YFM250XHN
“Warrior” (Calif.)
YFM350XNC
“Banshee”
YFZ350N
“Grizzly”
YFM600FN
“Grizzly Realtree Hunter”
YFM600FHN
PAGE 2 of 3
Assembly
Manual
LIT-11666-13-34
Same as
YFM400NM
Service
Manual
LIT-11616-BB-2K
Same as
YFM400FWNM
LIT-11616-FW-00
Same as
YFM600FWAM
2001 ATV Service Literature
Other Publications
ATV Warranty Statement*
ATV Safety Alert
Ride Safe, Ride Smart Videotape
ATV Rally CD-ROM
Used ATV Safety Verification Form
Y-12 Hang Tag (Badger only)
Sport Hang Tag (Raptor, Banshee, Warrior, Blaster)
General Hang Tag (all others)
Tips and Practice Guide for the ATV Rider
ATV Set-Up and Predelivery Checklist
2000 ATV Flat Rate Manual
ATV Technical Service Data (1998, 1999, 2000)
Y.E.S. Plan Highlights
Sample Y.E.S. Contract
Warranty and Y.E.S. Handbook
Parts System Handbook
Part Number
LIT-11790-02-86
LIT-17451-00-99
VID-17299-00-00
LIT-17299-CD-00
LIT-17299-01-2K
2FJ-2819R-00-00
3JM-2819R-00-96
3FA-2819R-00-00
LIT-17750-00-2K
LIT-17161-01-2K
LIT-17750-00-2K
LIT-17571-SD-2K
LIT-11580-00-05
LIT-11580-00-27
LIT-11760-00-95
LIT-10080-07-01
*The Limited Warranty Statement is also printed in each Owner’s Manual.
ROUTE TO:
 SERVICE  PARTS  WARRANTY  SALES
PAGE 3 of 3
2001 MODELS
ATV Primary ID Numbers
The following is a comprehensive listing of Primary I.D. numbers for 2001 Yamaha ATV’s. The frame
numbers of a unit contains 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 all warranty documents. Production
started with the listed numbers below. For more Primary I.D. 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 microfiche or CD-ROM.
Model
Model Name
Model Code
Starting PID No.
YFM80N
Badger
79cc
4EMX
AB013-000004
YFM80HN
Badger Realtree Hunter
79cc
4EMX
AB013-000004
YFA-1NC
Breeze, CA
3FAU
AE01Y-000601
YFM80NC
YFA-1N
YFS200N
YFM25XN
Badger, CA
Breeze
Blaster
Bear Tracker
Displacement
79cc
124cc
124cc
195cc
230cc
4EMY
3FAT
5KJ4
4XEA
AB01Y-000402
AE013-000002
3JM03-019348
AG01Y-047201
YFM25XHN
Bear Tracker Realtree Hunter
230cc
4XEA
AG01Y-047201
YFM35FXN
Wolverine
348cc
4KBM
AH04Y-000756
YFZ350N
YFM35XN
YFM350XNC
YFM40N
Banshee
Warrior
Warrior, CA
347cc
348cc
348cc
Big Bear 2WD
386cc
Big Bear 4WD
386cc
Kodiak 2WD
401cc
Kodiak Realtree Hunter
401cc
5FKA
3GDY
5NF1
5GW4
3GG03-014443
3GD03-000006
AH01Y-002872
AH08Y-009501
YFM40HN
Big Bear 2WD Realtree Hunter 386cc
5GW4
AH08Y-009501
YFM40FHN
Big Bear 4WD Realtree Hunter 386cc
5FU9
AH06Y-403101
YFM4FAN
Kodiak 4WD
5GH9
AJ03Y-001162
YFM40FN
YFM400AN
YFM4FAHN
YFM600FN
YFM600FHN
YFM660RN
YFM660RNC
Grizzly
401cc
595cc
5FU6
5HA7
5GHF
5GTE
AH06Y-000101
AJ04Y-000351
AJ03Y-007257
AJ02Y-001510
Grizzly Realtree Hunter
595cc
5GTK
AJ02Y-010713
Raptor, CA
660cc
5LP3
AM013-000002
Raptor
ROUTE TO:
660cc
5lLP1
 SERVICE  PARTS  WARRANTY  SALES
AM013-000052
PAGE 1 of 1
© 2001 YAMAHA MOTOR CORPORATION, U.S.A.
’99 ~ ’00 MODELS
ATV Paint Reference Charts
This bulletin contains information regarding paint color codes for 1999 and 2000 model ATVs. The 1999
information has updates or corrections to the references contained in the Summer 1999 Paint Chart
Reference Guide (LIT-10030-PC-2K).
For easy reference, the 2000 information includes the color name used in sales literature and the colorcode designator used in the model name. Note that the Sales color names may be used for more than
one actual color. The 2000-model information also includes paint colors for frames, bumpers, and
wheels, where applicable.
All paint may be ordered through Color Rite:
Color Rite Distribution Company
11603 Groveland Ave.
Whittier, CA 90604
For info (562) 947-9796
Fax (562) 947-5087
To ORDER, CALL (800) 736-7980
Web Site: www.color-rite.com
E-mail: colorritebh@earthlink.com
When ordering, please provide Color Rite with the Year, Model, and Paint Code. Remember to provide
call-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’s
web page: www.color-rite.com.
NOTE: The following paint charts are also useful when ordering pre-painted parts from the Parts
Catalog. Paint codes are generally listed on the first page of the Parts catalog and next to the part number of the pre-painted or plastic body part. These charts can be used to confirm the color of the part you
are ordering. The Sales Color Name may be used for more than one paint color. The Sales Color Codes
have been included in the Color Name column in the year 2000 chart.
PAGE 1 of 5
Paint Chart Reference Guide
’99~’00 ATV Paint Reference Chart
ATV - 1999
Model
YFM600FL/C
Grizzly
YFM400FL/C
Kodiak
YFM350FXL/C
Wolverine
YFM350FHL/C
Big Bear 4WD
(Hunter Edition)
YFM350FL/C
Big Bear 4WD
YFB250FL
Timberwolf 4WD
YFM350UL/C
Big Bear 2WD
YFM250XL/C
BearTracker
YFA1L
Breeze
YFM80L
Badger
YFZ350L
Banshee
YFM350XL/C
Warrior
YFS200L
Blaster
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
PAGE 2 of 5
Component
Description
Color *
Beige
Green
Red
Green
Red
Green
Blue
Hunter Green
Paint Name
Dark Grayish Yellow Solid 1
Pastel Deep Green
Romantique Rouge
Pastel Deep Green
Romantique Rouge
Pastel Deep Green
Deep Purplish Blue Solid E
Pastel Deep Green
Abbreviation
DNYS1
PDG
RTR
PDG
RTR
PDG
DPBSE
PDG
Color
Code*
598
0K0
0TR
0K0
0TR
0K0
583
0K0
Beige
Green
Red
Green
Dark GrayishYellow Solid1
Pastel Deep Green
Romantique Rouge
Pastel Deep Green
DNYS1
PDG
RTR
PDG
598
0K0
0TR
0K0
Beige
Green
Red
Beige
Green
Red
White
Dark Grayish Yellow Solid 1
Pastel Deep Green
Romantique Rouge
Dark Grayish Yellow Solid 1
Pastel Deep Green
Romantique Rouge
Radical White
DNYS1
PDG
RTR
DNYS1
PDG
RTR
RW
598
0K0
0TR
598
0K0
0TR
0UJ
White
Radical White
RW
0UJ
Blue
Red
Dark Gray
White
Blue
White
Deep Purplish Blue Solid E
Romantique Rouge
Low Gloss Gray
Radical White
Deep Purplish Blue Solid E
Radical White
RTR
LGG
RW
DPBSE
RW
583
0TR
OT2
0UJ
583
0UJ
*Paint code
for reference
only - Do not
paint plastic
body parts.
*The Sales Color Name
is for unit color identification. The Sales Color
Name may be used for
more than one paint
color.
.
Paint Reference Chart
’99~’00 ATV Paint Reference Chart
ATV - 2000
Model
Model Code
Sales
Color Name*
Component
Paint
Color Name
Yamaha
Paint Code
Color-Rite
Paint Code
YFM600FHM / C
(Grizzly 4WD )
(w/ Camo Seat)
5GT9 / 5GTA
Hunter Green
(w/ Realtree X-tra® Seat)
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Low Gloss Black
Mat Black 2
00K0
0033
0098
0582
(PDG)
(YB)
(LGB)
(MBL2)
5822
5135
5654
5988
YFM600FM / C
(Grizzly 4WD)
5GT6 / 5GT7
Hunter Green (GR)
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Yamaha Black
Low Gloss Black
00K0
0033
0033
0098
(PDG)
(YB)
(YB)
(LGB)
5822
5135
5135
5654
Beige (E)
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Yamaha Black
Low Gloss Black
0598
0033
0033
0098
(DNYS1)
(YB)
(YB)
(LGB)
5901
5135
5135
5654
Red (R)
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Yamaha Black
Low Gloss Black
00TR
0033
0033
0098
(RTR)
(YB)
(YB)
(LGB)
5650
5135
5135
5654
Hunter Green (GR)
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Yamaha Black
Low Gloss Black
00K0
0033
0033
0098
(PDG)
(YB)
(YB)
(LGB)
5822
5135
5135
5654
Beige (E)
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Yamaha Black
Low Gloss Black
0598
0033
0033
0098
(DNYS1)
(YB)
(YB)
(LGB)
5901
5135
5135
5654
Red (R)
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Yamaha Black
Low Gloss Black
00TR
0033
0033
0098
(RTR)
(YB)
(YB)
(LGB)
5650
5135
5135
5654
YFM400AM / C
(Kodiak 2WD)
5HA1 / 5HA2
YFM400FAHM / C
(Kodiak 4WD)
(w/ Camo Seat)
5GH6 / 5GH7
Hunter Green
(w/ Realtree X-tra® Seat)
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Low Gloss Black
Mat Black 2
00K0
0033
0098
0582
(PDG)
(YB)
(LGB)
(MBL2)
5822
5135
5654
5988
YFM400FAM / C
(Kodiak 4WD)
5GH1 / 5GH2
Hunter Green (GR)
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Yamaha Black
Low Gloss Black
00K0
0033
0033
0098
(PDG)
(YB)
(YB)
(LGB)
5822
5135
5135
5654
Beige (E)
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Yamaha Black
Low Gloss Black
0598
0033
0033
0098
(DNYS1)
(YB)
(YB)
(LGB)
5901
5135
5135
5654
Red (R)
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Yamaha Black
Low Gloss Black
00TR
0033
0033
0098
(RTR)
(YB)
(YB)
(LGB)
5650
5135
5135
5654
*The Sales Color Name
is for unit color identification. The Sales Color
Name may be used for
more than one paint
color.
*Paint code for
reference only Do not paint
plastic body
parts.
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
The letter in parenthesis
is the Sales Color Code i.e. (R).
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 paints.
Continued on next page
PAGE 3 of 5
Paint Reference Chart
’99~’00 ATV Paint Reference Chart
ATV - 2000 (Cont’d)
Model
Sales
Color Name*
Model Code
Component
Paint
Color Name
Yamaha
Paint Code
Color-Rite
Paint Code
YFM400FHM
(Big Bear 4WD)
5FU5
Buckmaster Edition
(Realtree X-tra®)
Body*
Frame
Front Bumper
Wheel
N/A
Yamaha Black
Yamaha Black
Yamaha Black
0033
0033
0033
YFM400FM / C
(Big bear 4WD)
5FU1 / 5FU2
Hunter Green (GR)
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033
(YB)
00MA (TGM)
00MA (TGM)
5822
5135
5860
5860
Beige (E)
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
0598
0033
00MA
00MA
(DNYS1)
(YB)
(TGM)
(TGM)
5901
5135
5860
5860
Red (R)
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00TR
0033
00MA
00MA
(RTR)
(YB)
(TGM)
(TGM)
5650
5135
5860
5860
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033
(YB)
00MA (TGM)
00MA (TGM)
5822
5135
5860
5860
Beige (E)
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
0598
0033
00MA
00MA
(DNYS1)
(YB)
(TGM)
(TGM)
5901
5135
5860
5860
Red (R)
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00TR
0033
00MA
00MA
(RTR)
(YB)
(TGM)
(TGM)
5650
5135
5860
5860
Team Yamaha Blue (L)
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Yamaha Black
Silver
Silver
0583
0033
0035
0035
(DPBSE)
(YB)
(SL)
(SL)
5829
5135
5616
5616
Hunter Green (GR)
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0 (PDG)
0033
(YB)
00MA (TGM)
00MA (TGM)
5822
5135
5860
5860
Team Yamaha Blue / White (L)
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
N/A
0583
0035
0035
(DPBSE)
(SL)
(SL)
5829
5616
5616
Body*
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Radical White
Silver
Silver
N/A
00TR
00UJ
0035
0035
(RTR)
(RW)
(SL)
(SL)
5650
5457
5616
5616
YFM400M / C
(Big Bear 2WD)
YFM350FXM / C
(Wolverine 4WD)
YFZ350M
(Banshee)
5GW1 / 5GW2 Hunter Green (GR)
4KBG / 4KBH
5FK6
Red / White (W)
C - Designates
California Model
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
PAGE 4 of 5
(Red)
(White)
*The Sales Color Name
is for unit color identification. The Sales Color
Name may be used for
more than one paint
color.
The letter in parenthesis
is the Sales Color Code i.e. (R).
(YB)
(YB)
(YB)
5135
5135
5135
N/A - Not Available
*Paint code for
reference only Do not paint
plastic body
parts.
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 paints.
Continued on next page
Paint Reference Chart
’99~’00 ATV Paint Reference Chart
ATV - 2000 (Cont’d)
Model
YFM350XM / C
(Warrior)
Sales
Color Name*
Model Code
3GDU / 3GDV
Component
Paint
Color Name
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
N/A
0583
0035
0035
(DPBSE)
(SL)
(SL)
5829
5616
5616
Body*
(Red)
(White) Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Radical White
Silver
Silver
N/A
00TR
00UJ
0035
0035
(RTR)
(RW)
(SL)
(SL)
5650
5457
5616
5616
Team Yamaha Blue / White (L)
Red / White (W)
Yamaha
Paint Code
Color-Rite
Paint Code
YFB250FM
(Timberwolf)
4KDL
Hunter Green (GR)
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Silver
Silver
00K0
0033
0035
0035
(PDG)
(YB)
(SL)
(SL)
5822
5135
5616
5616
YFM250XM / C
(BearTracker)
4XE5 / 4XE6
Hunter Green (GR)
Body*
Frame
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00K0
0033
00MA
00MA
(PDG)
(YB)
(TGM)
(TGM)
5822
5135
5860
5860
Beige (E)
Body*
Frame
Front Bumper
Wheel
Dark Grayish Yellow Solid 1
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
0598
0033
00MA
00MA
(DNYS1)
(YB)
(TGM)
(TGM)
5901
5135
5860
5860
Red (R)
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Yamaha Black
Titanic Gray Metallic
Titanic Gray Metallic
00TR
0033
00MA
00MA
(RTR)
(YB)
(TGM)
(TGM)
5650
5135
5860
5860
Team Yamaha Blue / White (L)
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Silver
Silver
Silver
0583
0035
0035
0035
(DPBSE)
(SL)
(SL)
(SL)
5829
5616
5616
5616
Red / White (W)
(Red)
(White)
Body*
Body*
Frame
Front Bumper
Wheel
Romantique Rouge
Radical White
Silver
Silver
Silver
00TR
00UJ
0035
0035
0035
(RTR)
(RW)
(SL)
(SL)
(SL)
5650
5457
5616
5616
5616
YFS200M
(Blaster)
5KJ1
YFA1M / C
(Breeze)
3FAR / 3FAP
Blue / White (L)
(Blue)
(White)
Body*
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Radical White
Yamaha Black
Yamaha Black
Silver
0583
00UJ
0033
0033
0035
(DPBSE)
(RW)
(YB)
(YB)
(SL)
5829
5457
5135
5135
5616
YFM80M / C
(Badger)
4EMT / 4EMS
Blue / White (L)
(Blue)
(White)
Body*
Body*
Frame
Front Bumper
Wheel
Deep Purplish Blue Solid E
Radical White
Yamaha Black
Yamaha Black
Silver
0583
00UJ
0033
0033
0035
(DPBSE)
(RW)
(YB)
(YB)
(SL)
5829
5457
5135
5135
5616
*Paint code for
reference only Do not paint
plastic body
parts.
N/A - Not Available
C - Designates
California Model
*The Sales Color Name
is for unit color identification. The Sales Color
Name may be used for
more than one paint
color.
NOTE: When ordering
pre-painted or plastic
body parts from the
Parts Catalog, check
the first page of the
parts list, the code next
to the part number, and
this chart for color
verification.
ROUTE TO:
The letter in parenthesis
is the Sales Color Code i.e. (R).
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 paints.
✓ SERVICE ✓ PARTS ✓ WARRANTY ✓ SALES
PAGE 5 of 5
© 1999 YAMAHAMOTORCORPORATION, U.S.A.
2000 MODELS
ATV SERVICE LITERATURE
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.
Model
Actual
Displacement
Owner’s
Manual
Assembly
Manual
Service
Manual
ì Badgerî
YFM80M
79
LIT-11626-13-03
LIT-11666-08-19
ì Badgerî (Calif.)
YFM80MC
79
LIT-11626-13-28
LIT-11666-08-19
î Breezeî
YFA1M
124
LIT-11626-13-04
LIT-11666-06-75
î Breezeî (Calif.)
YFA1M
124
LIT-11626-13-04
LIT-11666-06-75
ì Blasterî
YFS200M
195
LIT-11626-13-07
LIT-11666-07-20
LIT-11616-08-19
LIT-11616-13-28
(Supplement)
LIT-11616-08-19
LIT-11616-13-28
(Supplement)
LIT-11616-YF-00
* LIT-11616-13-04
(Supplement)
LIT-11616-YF-00
* LIT-11616-13-04
(Supplement)
LIT-11616-07-20
ì Bear Trackerî
YFM250XM
229.6
LIT-11626-13-14
LIT-11666-12-01
LIT-11616-12-01
ì Bear Trackerî (Calif.)
YFM250XMC
229.6
LIT-11626-13-14
LIT-11666-12-01
LIT-11616-12-01
ì Timberwolfî 4WD
YFB250FWM
229.6
LIT-11626-13-02
LIT-11666-09-80
LIT-11616-09-11
ì Wolverineî
YFM350FXM
348
LIT-11626-13-05
LIT-11666-09-58
LIT-11616-FX-36
* LIT-11616-12-03
* LIT-11616-13-05
(Supplements)
*This supplement is included in the main book, but is also available separately.
PAGE 1 of 3
2000 ATV Service Literature
Model
Actual
Displacement
Owner’s
Manual
Assembly
Manual
Service
Manual
ì Wolverineî (Calif.)
YFM350FXMC
348
LIT-11626-13-05
LIT-11666-09-58
ì Warriorî
YFM350XM
348
LIT-11626-13-08
LIT-11666-08-60
ì Warriorî (Calif.)
YFM350XMC
348
LIT-11626-13-08
LIT-11666-08-60
ì Bansheeî
YFZ350M
347
LIT-11626-13-09
LIT-11666-07-86
ì Kodiakî 2WD
YFM400AM
386
LIT-11626-13-39
LIT-11666-13-39
ì Kodiakî 2WD (Calif.)
YFM400AMC
386
LIT-11626-13-39
LIT-11666-13-39
ì Kodiakî 4WD
YFM400FAM
386
LIT-11626-13-21
LIT-11666-13-21
LIT-11616-FX-36
* LIT-11616-12-03
* LIT-11616-13-05
(Supplements)
LIT-11616-YM-36
LIT-11616-10-89
(Supplement)
LIT-11616-YM-36
LIT-11616-10-89
(Supplement)
LIT-11616-YF-35
LIT-11616-10-95
(Supplement)
LIT-11616-13-21
LIT-11616-13-39
(Supplement)
LIT-11616-13-21
LIT-11616-13-39
(Supplement)
LIT-11616-13-21
ì Kodiakî 4WD (Calif.)
YFM400FAMC
386
LIT-11626-13-21
LIT-11666-13-21
LIT-11616-13-21
ì Kodiak - Real Treeî 4WD
YFM400FAHM
386
LIT-11626-13-21
LIT-11666-13-21
LIT-11616-13-21
ì Kodiak Real Treeî 4WD(Calif.)
YFM400FAHMC
386
LIT-11626-13-21
LIT-11666-13-21
LIT-11616-13-21
ì Big Bearî 2WD
YFM400NM
386
LIT-11626-13-34
LIT-11666-13-34
ì Big Bearî 2WD (Calif.)
YFM400NMC
386
LIT-11626-13-34
LIT-11666-13-34
ì Big Bearî 4WD
YFM400FWNM
386
LIT-11626-13-22
LIT-11666-13-22
LIT-11616-13-22
LIT-11616-13-34
(Supplement)
LIT-11616-13-22
LIT-11616-13-34
(Supplement)
LIT-11616-13-22
ì Big Bearî 4WD (Calif.)
YFM400FWNMC
386
LIT-11626-13-22
LIT-11666-13-22
LIT-11616-13-22
ì Big Bear Buckmasterî 4WD
YFM400FWNHM
386
LIT-11626-13-22
LIT-11666-13-22
LIT-11616-13-22
ì Grizzlyî
YFM600FWAM
595
LIT-11626-13-06
LIT-11666-11-02
ì Grizzlyî (Calif.)
YFM600FWAMC
595
LIT-11626-13-06
LIT-11666-11-02
LIT-11616-FW-00
* LIT-11616-11-21
* LIT-11616-12-37
(Supplements)
LIT-11616-FW-00
* LIT-11616-11-21
* LIT-11616-12-37
(Supplements)
*This supplement is included in the main book, but is also available separately.
PAGE 2 of 3
2000 ATV Service Literature
Actual
Displacement
Owner’s
Manual
ì Grizzly - Real Treeî
YFM600FWHM
595
LIT-11626-13-06
LIT-11666-11-02
ì Grizzly Real Treeî (Calif.)
YFM600FWHMC
595
LIT-11626-13-06
LIT-11666-11-02
Model
Assembly
Manual
Service
Manual
LIT-11616-FW-00
* LIT-11616-11-21
* LIT-11616-12-37
(Supplements)
LIT-11616-FW-00
* LIT-11616-11-21
* LIT-11616-12-37
(Supplements)
*This supplement is included in the main book, but is also available separately.
PAGE 3 of 3
© 1999 YAMAHA MOTOR CORPORATION, U.S.A.
1999 MODELS
Effective 3/26/99, this Technial Bulletin replaces AT99-001; please remove and
destroy AT99-001.
Denotes a change in the original Technical Bulletin.
ATV PRIMARY I.D. NUMBERS & SERVICE LITERATURE
The following is a comprehensive listing of Primary I.D. numbers and service literature part numbers
for 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 all
warranty documents. Production started with the listed numbers below. For more details, see Technical
Bulletin 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.
Model
Actual
Starting
Displace- Frame Numbers
ment
(Primary I.D.)
Owner’s
Manual
Assembly
Manual
Service
Manual
LIT-11616-08-19
Same as
YFM80D~K
LIT-11616-06-75
Same as
YFA W~K
LIT-11616-07-20
Same as
YFS200U~K
LIT-11616-09-11
Same as
YFB250H~K
LIT-11616-12-01
“Badger”
YFM80L
79
4EM-095264
LIT-11626-12-50
”Breeze”
YFA1L
124
3FA-107718
LIT-11626-12-44
“Blaster”
YFS200L
195
3JM-289187
LIT-11626-12-51
“Timberwolf”
YFB250FWL
229.6
4KD-118196
LIT-11626-12-45
“Bear Tracker”
YFM250XL
229.6
AG01W-000102
LIT-11626-12-46
LIT-11666-08-19
Same as
YFM80D~K
LIT-11666-06-75
Same as
YFA W~K
LIT-11666-07-20
Same as
YFS200A~K
LIT-11666-09-80
Same as
YFB250H~K
LIT-11666-12-01
”Bear Tracker” (Calif.)
YFM250XLC
229.6
AG01Y-000101
LIT-11626-12-46
LIT-11666-12-01
LIT11616-12-01
“Big Bear”4WD
YFM350FWBL
348
4WU-057914
LIT-11626-12-48
LIT-11666-10-58
Same as
YFM350FWB J~K
LIT-11616-10-58
Same as
YFM350FWB J~K
LIT-11616-10-93
LIT-11616-12-10
(Supplements)
PAGE 1 of 2
1999 ATV Primary ID Numbers & Service Literature
Actual
Starting
Displace- Frame Numbers
Model
ment
(Primary I.D.)
Owner’s
Manual
Assembly
Manual
“Big Bear”4WD (Calif.)
YFM350FWBLC
348
AH02Y-000328
LIT-11626-12-48
LIT-11666-10-58
Same as
YFM350FWB J~K
“Big Bear”2WD
YFM350UBL
348
AH03W-000007
LIT-11626-12-49
LIT-11666-10-08
Same as
YFM350UB H~K
“Big Bear”2WD (Calif.)
YFM350UBLC
348
AH03Y-000001
LIT-11626-12-49
LIT-11666-10-08
Same as
YFM350UB H~K
“Wolverine”
YFM35FXL
348
4KB-078283
LIT-11626-12-47
LIT-11666-09-58
”Wolverine”(Calif.)
YFM35FXLC
348
AH04Y-000003
LIT-11626-12-47
LIT11666-09-58
“Warrior”
YFM350XL
348
3GD-225942
LIT-11626-12-53
LIT-11666-08-60
Same as
YFM350X E~K
“Warrior”(Calif.)
YFM350XLC
348
4KD-118196
LIT11626-12-53
LIT-11666-08-60
Same as
YFM350X E~K
”Banshee”
YFZ350L
347
3GG-150917
LIT-11626-12-52
LIT11666-07-86
Same as
YFM350X B~K
“Kodiak”4WD
YFM400FWBL
386
AH05W-000018
LIT11626-12-24
LIT-11666-12-24
“Kodiak” 4WD (Calif.)
386
AH05Y-000001
LIT-11626-12-24
LIT-11666-12-24
“Grizzly”
YFM600FWAL
595
AJ02W-000020
LIT-11626-12-37
LIT-11666-11-02
“Grizzly” (Calif.)
YFM600FWALC
595
AJ02Y-000001
LIT-11626-12-37
LIT-11666-11-02
YFM400FWBLC
PAGE 2 of 2
Service
Manual
LIT-11616-10-58
Same as
YFM350FWB J~K
LIT-11616-10-93
LIT-11616-12-10
(Supplements)
LIT-11616-10-08
Same as
YFM350UB H~K
LIT-11616-12-02
(Supplement)
LIT-11616-10-08
Same as
YFM350UB H~K
LIT-11616-12-02
(Supplement)
LIT-11616-FX-35
Same as
YFM350FX G~K
LIT-11616-FX-35
Same as
YFM350FX G~K
LIT-11616-YM-36
Same as
YFM350X A~K
LIT-11616-10-89
LIT-11616-10-28
(Supplements)
LIT-11616-YM-36
Same as
YFM350X A~K
LIT-11616-10-89
LIT-11616-10-28
(Supplements)
LIT-11616-YF-35
Same as
YFM350X T~K
LIT-11616-10-95
(Supplement)
LIT-11616-KD-40
Same as
YFM400FWB E~K
LIT-11616-12-24
(Supplement)
LIT-11616-KD-40
Same as
YFM400FWB E~K
LIT-11616-12-24
(Supplement)
LIT-11616-11-02
Same as
YFM600FWAK
LIT-11616-12-37
LIT-11616-11-21
(Supplements)
LIT-11616-11-02
Same as
YFM600FWAKC
LIT-11616-12-37
LIT-11616-11-21
(Supplements)
1998 ATV Primary ID Numbers & Service Literature
1997 ATV Primary ID Numbers & Service Literature
ATV
Service Data
YFM50
Service Data
2004~2008
“Raptor 50”
(5YF)
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
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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
YFM80
Service Data
1995~2001
“Badger”
(4EM)
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
YFM80 1995~2001
“Badger”
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 3.0A @ 8000 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
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W
Torque Values:
Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 Lever . . . . . . . . . . . . . . . . . . . . . . . . 1NV-83912-00-00
YFM80G
Service Data
2005~2008
“Grizzly 80”
(2D3)
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:
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 (0.0 ~ 0.39 in)
TIRES:
Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT18 x 7-7
- Nominal Pressure . . . . . . . . . . . . . . . . . 17 ~ 23kPa (2.5 ~ 3.3 psi)
Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT18 x 7-8
- Nominal Pressure . . . . . . . . . . . . . . . . . 17 ~ 23kPa (2.5 ~ 3.3 psi)
June 2009
YFM80G 2005~2008
“Grizzly 80”
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 3.0A @ 8000 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
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W
Torque Values:
Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 Lever . . . . . . . . . . . . . . . . . . . . . . . . 23X-83912-00-00
YFM80W
Service Data
2002~2008
“Raptor 80”
(5TH)
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:
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 (0.0 ~ 0.39 in)
TIRES:
Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT18 x 7-7
- Nominal Pressure . . . . . . . . . . . . . . . . . 17 ~ 23kPa (2.5 ~ 3.3 psi)
Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT18 x 7-8
- Nominal Pressure . . . . . . . . . . . . . . . . . 17 ~ 23kPa (2.5 ~ 3.3 psi)
June 2009
YFM80W 2002~2008
“Raptor 80”
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 3.0A @ 8000 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
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W
Torque Values:
Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M12: 2.0m-kg (14
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . . M12: 7.0m-kg (50
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 Lever . . . . . . . . . . . . . . . . . . . . . . . . 1NV-83912-00-00
YFM90R
Service Data
2009~
“Raptor 90”
(43D)
ENGINE:
Engine Type . . . . . . . . . . . . . Air Cooled, 4-Stroke, Single Cylinder, SOHC
Bore 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, 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 . . . . . . . . . . . . . . . . . 0.80 L (0.85 US qt)
- Oil Change Only . . . . . . . . . . . . . . . . . . . . . 0.75 L (0.80 US qt)
FUEL SYSTEM:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor
Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . TK / SVR 22-1G
Main Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 / 32
Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . 2.090 H5.5 / 4T12 1
Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / 2.3
Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5mm (1.00 in)
Fuel Level . . . . . . . . . . . . . . . . . . . . . . 5.0 ~ 6.0mm (0.20 ~ 0.24 in)
Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600 ~ 1800 rpm
Set 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 Automatic
Oil 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear - 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
YFM90R 2009~
“Raptor 90”
Service Data
ignition system:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI
Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR7HSA
Spark Plug Gap . . . . . . . . . . . . . . . . . 0.6 ~ 0.7mm (0.024 ~ 0.028 in)
Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0KΩ
Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)
Primary Ω / Secondary Ω . . . . . . . . . . . . 0.189 ~ 0.231Ω / 2.79 ~ 3.41KΩ
Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . W/L ~ W/R / 94 ~ 140Ω
Source Coil Color Code / Ω . . . . . . . . . . . . . . . B/G ~ B/R / 640 ~ 960Ω
charging system:
Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto
Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . GTX5L - BS
System Maximum Output . . . . . . . . . . . . . . . . 14.0V, 85 W @ 5000 RPM
Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . . W ~ W / 0.60 ~ .90Ω
lighting system:
System Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Lighting Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
torque 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-A0-00
Oil Filter Type / Part Number . . . . . . . . . . . . . Strainer / 43D-E3411-00-00
Air 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-00-00
Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . 43D-F5906-00-00
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . 43D-H2151-00-00 (10A)
Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . 43D-E319C-00-00
Float Valve Needle . . . . . . . . . . . . . . . . . . . . . . . 43D-E4392-00-00
Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . 5WB-E4384-00-00
V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43D-E7641-00-00
4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . Yamlube 20W50
4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . Yamalube 10W40
4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . Yamalube 05W30 / 05W40
Transmission Oil . . . . . . . . . Yamalube Friction Modified Shaft Drive Gear Oil
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTG-GTX5L-BS-00
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 43D-F6311-00-00
Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 43D-F6331-00-00
Front Brake Cable . . . . . . . . . . . . . 43D-F6340-00-00, 43D-F6350-00-00
Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 43D-H3922-00-00
Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 43D-H3912-00-00
YFA1
Service Data
1995~2004
“Breeze”
(3FA)
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
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M16: 7.0m-kg (50
Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 12.0m-kg (87
Rear Axle Nut (See Service Manual for Procedure) . . . M38 24.0m-kg (170
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
TUNE UP / MAINTENANCE PARTS:
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
YFM125G
Service 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)
June 2009
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M10: 1.3m-kg (9.4
Front Wheel Nut / Rear . . . . . . M10: 5.5m-kg (40 ft-lb) / M10: 5.5m-kg (40
Front Hub Nut / Rear . . . . . . M16: 7.0m-kg (50 ft-lb) / M16: 12.0m-kg (87
Rear Axle Nut (See Service Manual for Procedure) . . . M33 24.0m-kg (170
Chain Adjuster Lock Nuts . . . . . . . . . . . . . . . . . . M8: 1.6m-kg (11.0
Drive Sprocket Nuts . . . . . . . . . . . . . . . . . . . . . M12: 7.5m-kg (54
Driven Sprocket Nuts . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
TUNE UP / MAINTENANCE PARTS:
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
YFS200
Service Data
1995~2006
“Blaster”
(5VM)
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
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M14: 2.5m-kg (18
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M14: 7.0m-kg (51
Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32
Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 12.0m-kg (87
Rear Axle Nut (See Service Manual for Procedure) . . . M38: 24.0m-kg (170
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
TUNE UP / MAINTENANCE PARTS:
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
YFB250
Service Data
1995~1998
“Timberwolf 2WD”
(4BD)
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:
Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle”
- Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil
- Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.13L (0.14 US qt)
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
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
TUNE UP / MAINTENANCE PARTS:
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
YFB250F
Service Data
1995~2000
“Timberwolf 4WD”
(4KD)
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:
Rear Drive Type . . . . . . . . . . . . . . . . . . . . . . . Gear Drive “Live Axle”
- Oil Type . . . . . . . . . . . . . . . . . SAE 80 API “GL-4” Hypoid Gear Oil
- Periodic Oil Change Capacity . . . . . . . . . . . . . . . 0.13L (0.14 US qt)
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
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
TUNE UP / MAINTENANCE PARTS:
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
YFM25B
Service Data
2005~
“Bruin 250/Big Bear 250”
(1P0)
ENGINE:
Engine Type . . . . . . . . . . . . . . . . . . . . . . Air Cooled 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, 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 . . . . . . . . . . . . . . . . . . . 1.6L (1.7 US qt)
- Oil Change Only . . . . . . . . . . . . . . . . . . . . . . . 1.5L (1.6 US qt)
FUEL SYSTEM:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor
Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33
Main Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.8 / 17.5
Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-2M / 5EP20
Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 2 / N/A
Float Height . . . . . . . . . . . . . . . . . . . . . . 12 ~ 14mm (0.47 ~ 0.55 in)
Fuel Level . . . . . . . . . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above
Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 ~ 1500 rpm
Set 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 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 (0.26 US qt)
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
YFM25B 2005~
“Bruin 250/Big Bear 250”
Service Data
ignition system:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-CDI
Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, DR7EA
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 / 168 ~ 252Ω
Rotation Sensor Coil Color Code / Ω . . . . . . . . . . R ~ W/L / 0.058 ~ 0.086Ω
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-5W
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W
torquetor values:
Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M35: 4.3m-kg (31
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
tune up / maintenance parts:
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-DR7EA-00-00
Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 5H0-13440-00-00
Air Filter Type / Part Number . . . . . . . . . . . . . . Paper / 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
Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 5GH-83516-00-00
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . 2GV-82151-00-00 (20A)
Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-347A1-00
Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00
Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00
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
Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00
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 or Clutch Lever . . . . . . . . . . . . . . . . . . . 2HT-83912-00-00
YFM25X
Service Data
1999~2004
“BearTracker”
(4XE)
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:
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 . . . . . . . . . . . . . . . 0.25L (0.26 US qt)
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
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22
Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
TUNE UP / MAINTENANCE PARTS:
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
YFM35BA
Service Data
2004~2006
“Bruin 2WD”
(5WH)
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:
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)
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
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
Front & Rear Caliper Bolts . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 / 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
YFM35FA
Service 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:
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 ~ 4.1 psi)
Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)
June 2009
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
Front & Rear Caliper Bolts . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 / 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
YFM35FG
Service Data
2007~
“Grizzly 350 4WD”
(5UH)
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:
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 (0.00 ~ 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
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
YFM35FGI
Service Data
2007~
“Grizzly 350 4WD IRS”
(4S2)
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:
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) 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
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
YFM35G
Service Data
2007~
“Grizzly 350 2WD”
(5WH)
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:
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)
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
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
YFM35X
Service Data
2006~
“Wolverine 350 2WD”
(3D5)
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, 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 . . . . . . . . . . . . . . . . . 2.20L (2.33 US qt)
- Oil Change Only . . . . . . . . . . . . . . . . . . . . . 2.30L (2.43 US qt))
FUEL SYSTEM:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor
Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33
Main Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . 128.8 / 17.5
Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-2M / 5ETY3
Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / N/A
Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm (0.51 in)
Fuel Level . . . . . . . . . . . . . . . . . . . . . 3 ~ 4mm (0.12 ~ 0.16 in) Above
Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ~ 1550 rpm
Set 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 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)
SUSPENSION:
Front - Toe-In . . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 5mm (0.0 ~ 0.2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT23 x 10-12
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)
June 2009
YFM35X 2006~
“Wolverine 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 / 0.104 ~ 0.127Ω
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:
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W
Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W
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: 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-00-00
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 123-83516-21-XX
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . 2GV-82151-00-00 (20A)
Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 93210-35512-00
Float Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . . 1UY-14107-20-00
Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 2LN-14147-00-00
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
Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YB12C-A0-00
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-26311-10-00
Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . 4KB-83550-00-00
Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-2637E-02-00
Front Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 4KB-26351-01-00
Rear Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 4KB-26341-00-00
Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 1UY-83922-01-00
Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 1UY-83912-01-00
YFM350ER
Service Data
1995
“Moto-4”
(3HP)
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
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
YFM350FW
Service Data
1995~1996
“Big Bear 4WD”
(3HN)
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:
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 . . . . . . . . . . . . . . . . . . . . . . 5 ~ 15mm (0.19 ~ 0.59 in)
- Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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)
April 2005
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M13: 13.0m-kg (94
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M13: 13.0m-kg (94
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 . . . . . . . . . . . . . . . . . . . . . . . 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
YFM350FWB
Service 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:
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 . . . . . . . . . . . . . . . . . . . . . . 5 ~ 15mm (0.19 ~ 0.59 in)
- Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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)
April 2005
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:
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M13: 13.0m-kg (94
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M13: 13.0m-kg (94
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 . . . . . . . . . . . . . . . . . . . . . . . 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
YFM350FWJ
Service Data
1997
“Big Bear SE 4WD”
(4WU)
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:
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 . . . . . . . . . . . . . . . . . . . . . . 5 ~ 15mm (0.19 ~ 0.59 in)
- Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tires:
Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12
- Nominal Pressure . . . . . . . . . . . . . 0.17 ~ 0.23 Kg/cm (2.5 ~ 3.3 psi)
Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)
April 2005
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:
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2V 25W-25W
Tailight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 7.5W
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W
Torque Values:
Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.2m-kg (23
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M13: 13.0m-kg (94
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nuts . . . . . . . . . . . . . . . . . . . . . . M13: 13.0m-kg (94
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 . . . . . . . . . . . . . . . . . . . . . . . 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
YFM35FX
Service Data
1995~2005
“Wolverine 4WD”
(4KB) (2D4)
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
YFM35FX 1995~2005
“Wolverine 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB12C-A
System Maximum Output . . . . . . . . . . . . . . . . . . 14V 12A @ 3000 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
TORQUE VALUES:
Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M34: 3.2m-kg (23
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 6.4m-kg (46
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22
Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 6.4m-kg (46
Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 . . . . . . . . . . . . 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
YFM350R
Service Data
2004~
“Raptor 350”
(5YT)
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:
Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 7-10
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)
Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 10-9
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)
April 2005
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:
Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto
Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB12C-A
System Maximum Output . . . . . . . . . . . . . . . . . . 14V 15A @ 5000 rpm
Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.51 ~ 0.63Ω
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32
Front Hub Nuts / Rear . . . . . M14: 8.5m-kg (61 ft-lb) / M16: 12.0m-kg (85
Front Caliper Bolts / Rear . . . . . . M8: 2.8m-kg (20 ft-lb) / M8: 2.3 m-kg (17
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 . . . . . . . . . . . . . . . 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
YFM350U
Service Data
1996~1999
“Big Bear 2WD”
(5FE)
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:
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 . . . . . . . . . . . . . . . 0.19L (0.20 US qt)
SUspension
Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ 0.39 in)
- Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tires:
Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)
Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 12-9
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.28 Kg/cm (3.2 ~ 4.1 psi)
April 2005
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
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 . . . . . . . . . . . . . . . . . . . . . . . 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
YFM350X
Service Data
1995~2004
“Warrior”
(5NF)
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:
Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 7-10
- Nominal Pressure . . . . . . . . . . . . . . . . . 22 ~ 28kPa (3.2 ~ 4.1 psi)
Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT22 x 10-9
- Nominal Pressure . . . . . . . . . . . . . . . . . 22 ~ 28kPa (3.2 ~ 4.1 psi)
June 2009
YFM350X 1995~2004
“Warrior”
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 / 0.270 ~ 0.330Ω
CHARGING SYSTEM:
Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto
Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YB12C-A
System Maximum Output . . . . . . . . . . . . . . . . . . 14V 15A @ 5000 rpm
Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.51 ~ 0.63Ω
LIGHTING SYSTEM:
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W
Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . 12V 21W-12V 5W
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3.4W
TORQUE VALUES:
Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M34: 3.2m-kg (23
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M14: 8.5m-kg (61
Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20
Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32
Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 12.0m-kg (85
Rear Axle Nut (See Service Manual for Procedure) . . . M38: 24.0m-kg (170
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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 . . . . . . . . . . . . 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
YFZ350
Service Data
1995~2006
“Banshee”
(5FK)
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
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
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M14: 2.0m-kg (14
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . M14: 8.5m-kg (61
Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . M8: 2.8m-kg (20
Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 4.5m-kg (32
Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 12.0m-kg (87
Rear Axle Nut (See Service Manual for Procedure) . . . M38: 24.0m-kg (170
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
TUNE UP / MAINTENANCE PARTS:
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
YFM4A
Service Data
2003~2004
“Kodiak 2WD”
(5VH)
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:
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)
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
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
YFM4FA
Service Data
2003~2004
“Kodiak 4WD”
(5TE)
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
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
YFM4FA
Service 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:
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
YFM4A 2005~2008
“Kodiak 4WD”
Service Data
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
YFM40
Service Data
2000~2004
“Big Bear 2WD”
(5GW)
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:
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 . . . . . . . . . . . . . . . 0.23L (0.24 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 11-10
- Nominal Pressure . . . . . . . . . . . . . . . . . 22 ~ 28kPa (3.2 ~ 4.1 psi)
April 2005
YFM40 2000~2004
“Big Bear 2WD”
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 1.7W
TORQUE VALUES:
Engine Drain Plug . . . . . . . . . . . . . . . . . . . . . M14: 3.2m-kg (23
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . M12: 1.8m-kg (13
Front Wheel Nut . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Front Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
Front Caliper Bolts . . . . . . . . . . . . . . . . . . . . . . M8: 3.0m-kg (22
Rear Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . M10: 5.5m-kg (40
Rear Hub Nut . . . . . . . . . . . . . . . . . . . . . . . M16: 15.0m-kg (110
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
ft-lb)
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)
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
YFM40F
Service Data
2000~2006
“Big Bear 4WD”
(5FU)
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 (23.61 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:
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 . . . . . . . . . . . . . . . 0.23L (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
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
YFM40FB
Service Data
2007~
“Big Bear 400 IRS”
(4S1)
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:
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 . . . . . . . . . . . . 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
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
YFM400A
Service Data
2000~2001
“Kodiak 2WD”
(5HA)
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:
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)
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
YFM400A 2000~2001
“Kodiak 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 / 0.104 ~ 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
YFM400F
Service Data
1995~1999
“Kodiak 4WD”
(5EH) (4SH) (4GB)
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 / 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:
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 . . . . . . . . . . . . . . . 0.19 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:
Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . . 0 ~ 10mm (0 ~ 0.39 in)
- Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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)
June 2009
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
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 . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . 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
YFM400FA
Service 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)
April 2005
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
YFM45FA
Service Data
2003~2004
“Kodiak 450 4WD”
(5ND)
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 . . . . . . . . . . . . . . . . . . . . . . . 2.3L (2.4 US qt)
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
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
- 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)
April 2005
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
YFM45FA“Kodiak 450 4WD”2005~2007
“Grizzly 450 4WD”
Service Data
(1D9)
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 . . . . . . . . . . . . . . . . . . . . . . . 2.3L (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 / 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
- 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
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
YFM45FG
Service Data
2008~
“Grizzly 450 4WD”
(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
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 . . . . . . . . . . . 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)
June 2009
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
yfm45fx
Service Data
2006~
“Wolverine 450 Sport 4WD”
(3c2)
ENGINE:
Engine Type . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHC
Bore 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, 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 / Pilot Screw (Turns Out) . . . . . . . . . . . 131.3 / 17.5 / 1.5
Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . P-0M / 5EP19
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 ~ 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 Reverse
Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø
V-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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear - 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)
June 2009
YFM45FX 2006~
“Wolverine 450 Sport 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 . . . . . . . . . . . . . . . . . . . . . . . . A/C Magneto
Maximum Output . . . . . . . . . . . . . . . . . . . . . . 14V 19A @ 5000 rpm
Battery - Manufacturer / Model . . . . . . . . . . . . . . . . . . . ø / YTX20L-BS
Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.50 ~ 0.62Ω
lighting system:
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W
Taillight / 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-00-00
Oil Filter Type / Part Number . . . . . . . . . . . . . Spin On / 5GH-13440-00-00
Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5UG-E4451-00-00
Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5UG-E4458-00-00
Front Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 3GD-W0045-00-00
Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 5GH-W0046-00-00
Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00
Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 256-84714-60-00
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-26311-01-00
Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 3C2-F6331-00-00
Park Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . 3C2-26341-00-00
YFZ450
Service 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)
June 2009
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
YFZ450
Service Data
2006~
“YFZ450”
(5TG) (5D3)
ENGINE:
Engine Type . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHC
Bore 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, 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 . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 / 42
Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . NA / NGNR
Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . 1 / 1.5
Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8mm (0.31 in)
Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 ~ 1850 rpm
Set 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 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)
- 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)
June 2009
YFZ450 2006~
“YFZ450”
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
Taillight / 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 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-CR8E0-00-00
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 . . . . . . . . . . . . . . . . . . . . . . . 5TG-W0045-00-00
Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 5LP-W0046-50-00
Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00
Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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
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 . . . . . . . . . . . . . . . . . . . 5TG-83912-00-00
YFZ450R
Service Data
2009~
“YFZ450R”
(18P)
ENGINE:
Engine Type . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, DOHC
Bore 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, 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 . . . . . . . . . . . . . . . . . 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 Engines
Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 1.25L (1.4 US qt)
FUEL SYSTEM:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection
Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / 42EHS
Main Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1950 ~ 2050 rpm
Set 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 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 / 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 Out
Rear - 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)
June 2009
YFZ450R 2009~
“YFZ450R”
Service Data
ignition system:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TCI-Digital
Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR8E
Spark Plug Gap . . . . . . . . . . . . . . . . . 0.7 ~ 0.8mm (0.028 ~ 0.031 in)
Spark Plug Cap Ω . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KΩ
Ignition Coil Test Gap . . . . . . . . . . . . . . . . . . . . . . . . 6mm (0.24 in)
Primary Ω / Secondary Ω . . . . . . . . . . . . . 2.16 ~ 2.64Ω / 8.64 ~ 12.96KΩ
Pickup Coil Color Code / Ω . . . . . . . . . . . . . . . . . . W ~ R / 248 ~ 372Ω
charging system:
Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . AC Magneto
Battery - Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YTZ-7S
System Maximum Output . . . . . . . . . . . . . . . . 14.0V 265 W @ 5000 rpm
Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.32 ~ 0.48Ω
lighting system:
Lighting Coil Color Code / Ω . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W
Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-CR8E0-00-00
Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 5D3-13440-00-00
Air Filter Type / Part Number . . . . . . . . . . . . . . Foam / 5TG-14451-00-00
Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5TG-14458-00-00
Front Brake Lining . . . . . . . . . . . . 5TG-W0045-20-00 / 5TG-W0045-30-00
Rear Brake Lining . . . . . . . . . . . . . . . . . . . . . . . 5TG-W0046-10-00
Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00
Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-84710-01-00
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . 2GH-82151-00-00 (20A)
Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 90430-10148-00
4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yamlube 20W50
4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yamalube 10W40
4 Stroke Oil . . . . . . . . . . . . . . . . . . . . . . . . Yamalube 5W30 / 5W40
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YTZ7S-HE-00
Battery Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 18P-82122-00-00
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 18P-26311-00-00
Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 5D3-83922-00-00
Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 5TJ-83912-00-00
YFM5FG/P
Service Data
2009~
“Grizzly 550 FI 4WD/EPS”
(28P) (34D)
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/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
YFM600FA
Service Data
1998
“Grizzly 4WD”
(4MV)
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:
Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic With Reverse
Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE
V-Belt Width / Limit . . . . . . . . . . . . . . 32.0mm (1.26 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 . . . . . . . . . . . . . . . 0.19L (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 . . . . . . . . . . . . . . . 0.67L (0.71 US qt)
Suspension:
Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . -5 ~ 5mm (-0.2 ~ 0.2 in)
Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tires:
Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.25 Kg/cm (3.2 ~ 3.6 psi)
Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.25 Kg/cm (3.2 ~ 3.6 psi)
April 2005
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
YFM600FA
Service Data
1999~2001
“Grizzly 4WD”
(5GT)
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:
Type . . . . . . . . . . . . . . . . . . . . . . V-Belt Fully Automatic With Reverse
Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE
V-Belt Width / Limit . . . . . . . . . . . . . . 32.0mm (1.26 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 . . . . . . . . . . . . . . . 0.19L (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 . . . . . . . . . . . . . . . 0.67L (0.71 US qt)
Suspension:
Front - Toe In . . . . . . . . . . . . . . . . . . . . . . . -5 ~ 5mm (-0.2 ~ 0.2 in)
Rear - Spring Preload (Std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tires:
Front - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 8-12
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.25 Kg/cm (3.2 ~ 3.6 psi)
Rear - Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT25 x 10-12
- Nominal Pressure . . . . . . . . . . . . . 0.22 ~ 0.25 Kg/cm (3.2 ~ 3.6 psi)
April 2005
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
YFM660F
Service Data
2002~2008
“Grizzly 660 4WD”
(5KM) (2C6) (23D)
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
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
YFM660R
Service Data
2001~2005
“660R Raptor”
(5LP)
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
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
YFM7FG/P
Service Data
2007~2008
“Grizzly 700 FI/EPS”
(5C0) (3B4)
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
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
YFM7FG/P
Service Data
2009~
“Grizzly 700 FI/EPS”
(5C0)(43P)
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 / 44EIS
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear - 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
YFM7FG/P 2009~
“Grizzly 700 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 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-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
Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
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
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-26311-20-00
Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3B4-2637F-10-00
Front Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 3B4-83922-00-00
Rear Brake or Clutch Lever . . . . . . . . . . . . . . . . . . . 3B4-83912-00-00
YFM70R
Service Data
2006~
“Raptor 700R”
(1S3)
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 . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (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 . . . . . . . . . . . . . . . . . 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 / 1.6L (1.7 US qt)
FUEL SYSTEM:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection
Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / 44EHS
Main Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 ~ 1700 rpm
Set 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 Manual
Oil Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . SEE ENGINE / ø
V-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 Out
Rear - 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
YFM70R 2006~
“Raptor 700R”
Service Data
ignition system:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TCI-DigitalI
Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CR8E
Spark Plug Gap . . . . . . . . . . . . . . . . . 0.7 ~ 0.9mm (0.028 ~ 0.031 in)
Spark Plug Cap Resistance 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 . . . . . . . . . . . . . . . . L/Y ~ G/W / 192 ~ 288Ω
charging system:
Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . A/C Magneto
Maximum Output . . . . . . . . . . . . . . . . . . . . . 14V 17.2A @ 5000 rpm
Battery - Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . ø / YT9-B4
Stator 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)
tune up / maintenance parts:
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . NGK-CR8E0-00-00
Oil Filter Type / Part Number . . . . . . . . . . . . Cartridge / 4X7-13440-01-00
Air Filter Type / Part Number . . . . . . . . . . . . . Washable / 1S3-14451-00-00
Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-14458-00-00
Front Brake Lining / Rear Brake Lining . . 1S3-W0045-00-00 / 1S3-W0046-00-00
Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00
Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-84710-00-00
Indicator Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3FV-83517-00-00
Main Fuse . . . . . . . . . . . . . . . . . . . . . 2GH-82151-00-00 Fuse (20A)
Drain Bolt Sealing Washer . . . . . . . . . . . . . . . . . . . . 214-11198-01-00
Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94582-13098-00
Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . 9383G-14231-00-00
Driven Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . 5TG-25438-10-00
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
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTY-YT9B4-00-00
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-26311-00-00
Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Clutch Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-26335-00-00
Reverse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 1S3-26150-00-00
Side x Side
Service Data
2009 Side x Side
Data Sheet Reference
Model
Market Name
Model
Code
YXR45FA
Rhino 450 4WD
2P5
YXR66F
Rhino 660 4WD
5UG
YXP700A
ProHauler 700
JW4
YXR70F
Rhino 700 FI
5B4 / 42S
YXP1000A
ProHauler 1000
JW5
2004
(S)
2005
(T)
2006
(V)
2007
(W)
2008
(X)
2009
(Y)
Data Sheet Reference
©2009 YAMAHA MOTOR CORPORATION, U.S.A.
All Rhino Models – V-Belt Information
The 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 Number
Model
Application
Top 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.
©2008 YAMAHA MOTOR CORPORATION, U.S.A.
ALL 2009 MODELS
Side x Side Starting Primary I.D. Numbers
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 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 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
AM21Y-0003001
YXR70SPY
Rhino 700 FI Sport Edition
686cc
5B4P
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
PAGE 1 of 1
©2008 YAMAHA MOTOR CORPORATION, U.S.A.
2008 MODELS
Side x Side Service Literature
Effective 4/12/09, this Technical Bulletin replaces SXS2008-003B; please remove and destroy
denotes a change.
SXS2008-003B. An
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
2), which can be ordered from Yamaha Parts and Accessories.
Service Manual
Model
Model Name
Owner’s Manual
(Main)
New ’08
’08 Supplement Compilation Manual
(Supplements Only)
(Main & Supplements)
Assembly
Manual
YXR70FX
Rhino 700 FI
LIT-11626-21-58
LIT-11616-21-58
N/A
N/A
LIT-11666-21-58
YXR70FSPX
Rhino 700 FI
Sport Edition
LIT-11626-21-59
LIT-11616-21-58
N/A
N/A
LIT-11666-21-58
YXR70FSP2X
Rhino 700 FI
Special Edition II
LIT-11626-21-65
LIT-11616-21-58
N/A
N/A
LIT-11666-21-58
YXR70FSEPX
Rhino 700 FI
Special Edition I
LIT-11626-21-58
LIT-11616-21-58
N/A
N/A
LIT-11666-21-58
YXR70FHX
Rhino 700 FI
LIT-11626-21-58
LIT-11616-21-58
N/A
N/A
LIT-11666-21-58
N/A
N/A
LIT-11666-21-58
Hunter Edition
YXR70FDUX
Rhino 700 FI
Ducks Unlimited
LIT-11626-21-58
LIT-11616-21-58
YXR45FX
Rhino 450
LIT-11626-21-21
YXR45FHW
LIT-11616-RH-45*
LIT-11616-21-21
LIT-11616-RH-46*
LIT-11666-19-43
YXR45FSPX
Rhino 450
LIT-11626-21-21
YXR45FSEW
LIT-11616-21-21
LIT-11616-RH-46*
LIT-11666-19-43
LIT-11616-21-21
LIT-11616-RH-46*
LIT-11666-19-43
Special Edition
YXR45FHX
Rhino 450 Hunter
LIT-11616-RH-45*
LIT-11626-21-21
YXR45FHW
LIT-11616-RH-45*
* The manual is a compilation of the related Service Manual and Supplements. This is the part number to order for a complete
manual.
PAGE 1 of 2
2008 Side x Side Service Literature
Order the following publications from Yamaha Parts and Accessories:
CATEGORY
Consumer
Side x Side Service
General Service &
Warranty
Yamaha Extended Service
(Y.E.S.)
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*
2006 and Later Side x Side Limited Warranty Statement*
LIT-11790-05-03
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
*The Limited Warranty Statement is also printed in each Owner’s Manual.
Model Year Suffix Letter Chart
Model Year
Suffix Letter
2004
2005
2006
2007
2008
S
T
V
W
X
PAGE 2 of 2
LIT-11790-65-06
Side x Side Dealer Setup & Predelivery Checklist
©2007 YAMAHA MOTOR CORPORATION, U.S.A.
ALL 2008 MODELS
Side x Side Starting Primary I.D. Numbers
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 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 P. I.D. Number
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
™
PAGE 1 of 1
©2007 YAMAHA MOTOR CORPORATION, U.S.A.
2007 MODELS
Side x Side Service Literature
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 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 2), which can be ordered from Yamaha Parts and Accessories.
Model
Model Name
Owner’s Manual
YXR66FW
Rhino 660
LIT-11626-20-51
YXR66FSPW
Rhino 660 4WD
LIT-11626-20-59
YXR66FSEW
Rhino 660 4WD
Special Edition
LIT-11626-20-51
YXR66FHW
Rhino 660 4WD
LIT-11626-20-51
Sport Edition
Hardwoods™
Hunter Edition Camo
YXR66FEXW
Rhino 660 4WD
Exploring Edition
LIT-11626-20-51
Hunter Green
YXR66FDUW
Service Manual
New ’07
’07 Supplement Compilation Manual
(Main)
(Supplements Only)
(Main & Supplements)
YXR66FAS
LIT-11616-20-51
LIT-11616-RH-68*
YXR66FAS
LIT-11616-20-51
LIT-11616-RH-68*
YXR66FAS
LIT-11616-RH-67
LIT-11616-20-51
LIT-11616-RH-68*
YXR66FAS
LIT-11616-20-51
LIT-11616-RH-68*
YXR66FAS
LIT-11616-20-51
LIT-11616-RH-68*
LIT-11616-RH-67
LIT-11616-RH-67
LIT-11616-RH-67
LIT-11616-RH-67
Assembly
Manual
YXR66FAV
LIT-11666-19-41
YXR66FSPW
LIT-11666-20-51
YXR66FAV
LIT-11666-19-41
YXR66FAV
LIT-11666-19-41
YXR66FAV
LIT-11666-19-41
Rhino 660 4WD
Ducks Unlimited
LIT-11626-20-51
YXR66FAS
LIT-11616-RH-67
LIT-11616-20-51
LIT-11616-RH-68*
YXR66FAV
LIT-11666-19-41
YXR45FW
Rhino 450
LIT-11626-20-50
YXR45FAV
LIT-11616-19-43
LIT-11616-20-50
LIT-11616-RH-45*
YXR45FAV
LIT-11666-19-43
YXR45FSEW
Rhino 450
LIT-11626-20-50
YXR45FAV
LIT-11616-20-50
LIT-11616-RH-45*
YXR45FHW
Rhino 450 Hunter
LIT-11626-20-50
LIT-11616-20-50
LIT-11616-RH-45*
Edition
Special Edition
LIT-11616-19-43
YXR45FAV
LIT-11616-19-43
YXR45FAV
LIT-11666-19-43
YXR45FAV
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 1 of 2
2007 Side x Side Service Literature
Order the following publications from Yamaha Parts and Accessories:
CATEGORY
PUBLICATIONS
2007 Rhino 660 Product Brochure
2007 Rhino Basic Orientation Video
Consumer
2007 Rhino Accessories and Apparel Brochure
2005 and Earlier Side x Side Limited Warranty Statement*
2006 and Later Side x Side Limited Warranty Statement*
LIT-19760-00-03
LIT-NER06-SS-01
LIT-17561-00-06
LIT-17500-AT-07
2001~2005 Technical Update DVD
LIT-175MT-R5-DV
2006 SxS Service Manuals CD
LIT-CDSRV-SS-06
2005 SxS Service Manuals CD
Heavy Duty Service Binder
LIT-CDSRV-SS-05
LIT-10501-01-80
Service Schedule Pad
LIT-11561-00-96
2005 SxS Flat Rate Manual
LIT-17750-SS-05
Parts System Handbook
LIT-10080-07-04
Y.E.S. Sample Contract
LIT-11580-00-38
Y.E.S. Used Hang Tag
LIT-11580-00-40
Warranty & Y.E.S. Handbook
Warranty Labor Rate Change Request
Y.E.S. Plan Highlights - Motorsports
Y.E.S. Registration Card
Y.E.S. Motorsports Hang Tag
Y.E.S. Used Unit Registration Card
LIT-11760-00-05
LIT-11791-02-02
LIT-11580-00-05
LIT-11580-00-04
LIT-11580-00-16
LIT-11580-00-19
Y.E.S. Motorsports Brochure
LIT-11580-00-36
Y.E.S. Request to Cancel Form
LIT-11580-00-10
Y.E.S. It Works DVD
DVD-10660-00-04
Y.E.S. Maintenance Log
Y.E.S. Plan Lienholder Information
*The Limited Warranty Statement is also printed in each Owner’s Manual.
Model Year Suffix Letter Chart
Model Year
Suffix Letter
2004
2005
2006
2007
S
T
V
W
PAGE 2 of 2
LIT-11790-65-06
Rhino 660 Side x Side CA Emission Control Warranty
2007 ATV/SxS Technical Update Book
Yamaha Extended Service
(Y.E.S.)
LIT-ATCAT-UT-07
LIT-11790-05-03
LIT-NER06-SS-02
Side x Side Dealer Setup & Predelivery Checklist
General Service &
Warranty
DVD-10660-00-15
YXR660FA Normalized Emissions Rating Hang Tag (EPA Requirements)
YXR45FA Normalized Emissions Rating Hang Tag (EPA Requirements)
Side x Side Service
PART NUMBER
LIT-RHINO-66-Y7
LIT-11580-00-03
LIT-11580-00-08
©2007 YAMAHA MOTOR CORPORATION, U.S.A.
ALL 2007 MODELS
Side x Side Starting Primary I.D. Numbers
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 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 P. I.D. Number
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
PAGE 1 of 1
©2006 YAMAHA MOTOR CORPORATION, USA
2006 MODELS
Side x Side Service Literature
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 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 2), which can be ordered from Yamaha Parts and Accessories.
Model
Model Name
Owner’s
Manual
Service
Manual
Supplement
Assembly
Manual
Combos
YXP700AVL
Pro Hauler 700 2WD
YXP700AS
LIT-11626-19-39
YXP700AS
LIT-11616-17-54
YXR66FAHV
Rhino 660 4WD
Hardwoods™
Hunter Edition Camo
LIT-11626-19-41
LIT-11616-RH-66 LIT-11616-19-41 LIT-11616-RH-67* LIT-11666-19-41
YXR66FAEXGV
Rhino 660 4WD
Exploring Edition
Hunter Green
LIT-11626-19-41
LIT-11616-RH-66 LIT-11616-19-41 LIT-11616-RH-67* LIT-11666-19-41
YXR66FAEXHV
Rhino 660 4WD
Exploring Edition
Hardwoods™
Hunter Camo
LIT-11626-19-41
LIT-11616-RH-66 LIT-11616-19-41 LIT-11616-RH-67* LIT-11666-19-41
YXR66FASEV
Rhino 660 4WD
Special Edition
LIT-11626-19-41
LIT-11616-RH-66 LIT-11616-19-41 LIT-11616-RH-67* LIT-11666-19-41
YXR66FAVGR
Rhino 660 4WD
LIT-11626-19-41
LIT-11616-RH-66
YXR45FAVGR
Rhino 450 4WD
LIT-11626-19-43
LIT-11616-19-43
YXP700AS
LIT-11666-17-54
LIT-11616-19-41 LIT-11616-RH-67* LIT-11666-19-41
LIT-11666-19-43
* The manual is a compilation of the related Service Manual and Supplements. This is the part number to order.
PAGE 1 of 2
2006 Side x Side Service Literature
Order the following publications from Yamaha Parts and Accessories:
CATEGORY
Consumer
Side x Side Service
General Service &
Warranty
Yamaha Extended Service
(Y.E.S.)
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
*The Limited Warranty Statement is also printed in each Owner’s Manual.
Model Year Suffix Letter Chart
Model Year
Suffix Letter
2004
2005
2006
S
T
V
PAGE 2 of 2
©2006 YAMAHA MOTOR CORPORATION, USA
ALL 2004 ~ 2006 MODELS
Side x Side Starting Primary I.D. Numbers
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. Number
YXR66FAS
Rhino 660 4WD
AM04Y-0000101
YXR66FAHS
Rhino 660 4WD Realtree Hardwoods Hunter Edition
AM06Y-0000101
YXP700S
ProHauler 700
JW41Y-0000101
YXP1000AS
ProHauler 1000
JW51Y-0000101
2005
Model
Model Name
Starting Primary I.D. Number
YXR66FAT
Rhino 660 4WD
AM04Y-0008901
YXR66FAHT
Rhino 660 4WD Realtree Hardwoods Hunter Edition
AM06Y-0003501
YXP700T
ProHauler 700
JW42Y-0000101
YXP1000AT
ProHauler 1000
JW52Y-0000101
2006
Model
Model Name
Starting Primary I.D. Number
YXR45FAVGR
Rhino 450 4WD
AJ19Y-0000101
YXR66FAVGR
Rhino 660 4WD
AM04Y-0019201
YXR66FASEV
Rhino 660 4WD Special Edition
AM08Y-0000101
YXR66FAEXHV
Rhino 660 4WD Realtree Hardwoods Exploring Edition
AM06Y-0008601
YXR66FAEXGV
Rhino 660 4WD Exploring Edition
AM04Y-0019201
YXR66FAHV
Rhino 660 4WD Realtree Hardwoods Hunter Edition
AM06Y-0008601
YXP700AVL
ProHauler 700
JW42Y-0001201
PAGE 1 of 1
2005 Side x Side Service Literature
© 2004 YAMAHA MOTOR CORPORATION, U.S.A.
2004/2005 MODELS
Side 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 East
is for dealers East of the Mississippi River. Color Rite West is for dealers West of the Mississippi. Please
note the new addresses below:
Color Rite Distribution Company
Color Rite East
123 Blaine St.
East Bangor, PA 18013
800-358-1882 - Order
610-588-7355 - Tech
610-588-1570 - Fax
Color Rite Dist. Co. (West)
1817 E. Ave. Q Ste. C-24
Palmdale, CA 93550
800-736-7980 - Order
661-266-1944 - Tech
661-266-0286 - Fax
E-Mail: colorritewtr@earthlink.net
Web Site: www.color-rite.com
As an added benefit, orders received by 2:00 pm (Eastern Standard Time for Color Rite East and Pacific
Standard Time for Color Rite West) will be shipped the same day.
When ordering, please provide Color Rite with the Year, Model, and Paint Code. Remember to provide
call 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 web page:
www.color-rite.com
NOTE: The following paint chart is also very useful when ordering pre-painted and plastic body parts
from the parts catalog. Paint codes are generally listed next to the part number of the pre-painted or
plastic body part. This chart can be used to confirm the color of the part you are ordering. The Sales
color name may be used for more than one paint color.
PAGE 1 of 2
2004/2005Side
Sidex xSide
Side
Paint
Reference
Chart
2004/2005
Paint
Reference
Chart
Model
Code
Model
Sales Color Name
Component
Paint Color Name
Yamaha Paint Code
(Paint Code Abbr.)
Color-Rite
Paint Code
Rhino 660
“Rhino 660 Auto 4x4”
YXR660FAHS/FAHT
“Rhino 660 Auto 4x4”
YXR660FAS/FAT
5UG3/
5UG8
Hunter Edition
(Realtree Hardwoods®
High Definition
Camouflage)
Body*
Frame
Roof Support
Front Bumper
Wheel
N/A
Yamaha Black
Yamaha Black
Chijimi Black
Low Gloss Black
0033
0033
00W0
0098
(YB)
(YB)
(WVB)
(LGB)
5135
5135
5187^
5654
5UG1/
5UG4
Hunter Green
Body*
Frame
Roof Support
Front Bumper
Wheel
Pastel Deep Green
Yamaha Black
Yamaha Black
Chijimi Black
Low Gloss Black
00K0
0033
0033
00W0
0098
(PDG)
(YB)
(YB)
(WVB)
(LGB)
5822
5135
5135
5187^
5654
JW51/
JW52
Steel Blue
Body*
Frame
Front Bumper
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Yamaha Black
Low Gloss Black
0891
0033
0033
0098
(DPBSN)
(YB)
(YB)
(LGB)
5290
5135
5135
5654
JW41/
JW42
Steel Blue
Body*
Frame
Front Bumper
Wheel
Dark Purplish Blue Solid N
Yamaha Black
Yamaha Black
Low Gloss Black
0891
0033
0033
0098
(DPBSN)
(YB)
(YB)
(LGB)
5290
5135
5135
5654
Pro Hauler
“Pro Hauler 1000 Auto”
YXP1000AS/AT
“Pro Hauler 700 Auto”
YXP700AS/AT
Model
codes
can be
used to
confirm
the model
year of
the unit.
Sales Color Name is
for unit color
identification and may
be used for more than
one paint color.
*Paint code for
reference only Do not paint
plastic body.
N/A - Not Available
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.
NOTE: When ordering pre-painted parts from the Parts Catalog,
check the code next to the part number and this chart for color verification.
PAGE 2 of 2
ROUTE TO:
SERVICE PARTS WARRANTY SALES
5187^ is not
textured.
© 2004 YAMAHA MOTOR CORPORATION, U.S.A.
2004 MODELS
Side x Side Service Literature
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 literature
part numbers will be listed, but “Same as . . .” will appear in the appropriate Manual column. 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 2), which can be ordered from Yamaha Parts and Accessories.
Model
YXP1000AS
Model Name
ProHauler 1000
Owner’s
Manual
LIT-11626-17-54
Service
Manual
LIT-11666-17-54
LIT-11616-17-23
LIT-11666-17-23
ProHauler 700
LIT-11626-17-54
LIT-11616-17-54
YXR66FAS
Rhino 660 4x4
LIT-11626-17-23
LIT-11616-17-23
Rhino 660 4x4
Hardwoods™
Hunter Edition
LIT-11626-17-23
Assembly
Manual
LIT-11616-17-54
YXP700AS
YXR66FAHS
Supplement
LIT-11666-17-54
LIT-11666-17-23
PAGE 1 of 2
2004 Side x Side Service Literature
Order the following publications from Yamaha Parts and Accessories:
CATEGORY
PUBLICATIONS
LIT-11660-RH-Y4
Rhino 660 Basic Orientation Video
VID-10660-00-88
2004 ProHauler Product Brochure
Consumer
2004 Rhino Accessories Brochure
General Service &
Warranty
Side x Side Dealer Setup & Predelivery Checklist
LIT-17561-00-03
LIT-19760-00-03
2004 MCY/ATV/SxS Technical Update Book
LIT-17500-00-04
Service Schedule Pad
LIT-11561-00-96
Heavy Duty Service Binder
Warranty & Y.E.S. Handbook
LIT-10501-01-80
LIT-11760-00-03
Warranty Labor Rate Change Request
LIT-11791-02-02
Y.E.S. Plan Highlights - Motorsports
LIT-11580-00-05
Y.E.S. Registration Card
LIT-11590-00-04
Parts System Handbook
Y.E.S. Used Hang Tag
Y.E.S. Motorsports Hang Tag
LIT-10080-07-01
LIT-11580-00-38
LIT-11580-00-40
LIT-11580-00-16
Y.E.S. Used Unit Registration Card
LIT-11580-00-19
Y.E.S. Maintenance Log
LIT-11580-00-03
Y.E.S. Motorsports Brochure
Y.E.S. Request to Cancel Form
Y.E.S. Plan Lienholder Information
Y.E.S. It Works Video
*The Limited Warranty Statement is also printed in each Owner’s Manual.
PAGE 2 of 2
LIT-10080-RN-04
LIT-11790-05-03
Y.E.S. Sample Contract
Yamaha Extended Service
(Y.E.S.)
LIT-HAULR-20-04
Side x Side Limited Warranty Statement*
Rhino 660 Side x Side CA Emission Control Warranty
Side x Side Service
PART NUMBER
2004 Rhino 660 Product Brochure
ROUTE TO:
LIT-11580-00-36
LIT-11580-00-10
LIT-11580-00-08
VID-10660-00-78
✓ SERVICE ✓ PARTS ✓ WARRANTY ✓ SALES
YXR45F
Service Data
2006~
“Rhino 450 4WD”
(2P5)
ENGINE:
Engine Type . . . . . . . . . . . . . . . . . . . . Liquid Cooled 4 Cycle, SOHC
Bore 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, 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 . . . . . . . . . . . . . . . . . . 2.6L (2.75 US qt)
- Oil Change Only . . . . . . . . . . . . . . . . . . . . . . 2.5L (2.64 US qt)
COOLING SYSTEM:
Coolant Type . . . Ethylene Glycol with Corrosion Inhibitors for Aluminum Engines
Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . . 1:1 / 2.7L (2.85 US qt)
FUEL SYSTEM:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Carburetor
Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / BSR33
Main Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.8 / 20
Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . P-0M / 5ERB1
Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . 1 / 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 ~ 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 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 . . . . . . . . . . . . . . . 0.25L (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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear - 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
YXR45F 2006~
“Rhino 450 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 . . . . . . . . . . . . . . . . . . . . . . N/A
charging system:
Charging System Type . . . . . . . . . . . . . . . . . . . . . . . . A/C Magneto
Maximum Output . . . . . . . . . . . . . . . . . . . . . . 12V 28A @ 5000 rpm
Battery - Manufacturer / Model . . . . . . . . . . ø / Wet Type, U1 Group Rating
Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.32 ~ 0.39Ω
lighting system:
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W
Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1.7W x 5
torque 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/A
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 / 5UG-E4451-00-00
Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5UG-E4458-00-00
Front / Rear Brake Lining . . . . . . . . . 3LD-W0045-00-00 / 5UG-W0046-00-00
Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00
Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-000
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 5UH-14107-10-00
Float Bowl O-Ring / Gasket . . . . . . . . . . . . . . . . . . . 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 (22°F) . . . . . . . . . . . . . . . 5W40 or 5W30 Yamalube
Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00
Rear Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . ACC-SHAFT-LU-00
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5UG-H2100-00-00
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . A5UG-26311-00-00
Starter Cable (Choke) . . . . . . . . . . . . . . . . . . . . . . 2P5-26331-00-00
Park Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . 2P5-26341-00-00
YXR66F
Service Data
2004~2007
“Rhino 660 4WD”
(5UG)
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
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
YXP700a
Service Data
2004~2006
“ProHauler 700”
(JW4)
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
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
YXR70F
Service Data
2008~
“Rhino 700 FI”
(5B4) (42S)
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 (0.004 ~ 0.005 in)
- Exhaust . . . . . . . . . . . . . . . . . . 0.16 ~ 0.20mm (0.006 ~ 0.008 in)
Premix Oil Type / Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
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 . . . . . . . . . . . . . . . . . 2.1 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 Engines
Coolant Ratio / Capacity . . . . . . . . . . . . . . . . . 1:1 / 2.35 L (2.48 US qt)
FUEL SYSTEM:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection
Manufacturer / Model . . . . . . . . . . . . . . . . . . . . . . . Mikuni / 41EHS
Main Jet / Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Pilot Screw (Turns Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Needle Jet / Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Clip Position / Slide Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Float Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 ~ 1650
Set CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ~ 10%
Fuel Tank Capacity - Main / Reserve . . . . . . . . . . . 30 L (7.9 US gal) / N/A
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) / 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
YXR70F 2008~
“Rhino 700 FI”
Service Data
ignition system:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC-TCI
Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . NGK, CPR7EA-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 . . . . . . . . . . . . . 2.16 ~ 2.64Ω / 8.64 ~ 12.96KΩ
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 . . . . . . . . . . . . . . . Wet Type, U1 Group Rating 340 CCA
System Maximum Output . . . . . . . . . . . . . . . . . 14V 33.5A @ 5000 rpm
Stator Coil Color Code / Ω . . . . . . . . . . . . . . . . . W ~ W / 0.13 ~ 0.15Ω
lighting system:
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 30W-30W
Taillight / Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W-5W
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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)
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 / 5BR-E4451-00-00
Air Filter Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5B4-E4472-00-00
Front Brake Lining . . . . . . . . . . . . . 5B4-W0045-00-00 / 5B4-W0045-10-00
Rear Brake Lining . . . . . . . . . . . . . 5B4-W0045-00-00 / 5B4-W0045-10-00
Parking Brake Lining . . . . . . . . . . . . . . . . . . . . . . 5B4-W0046-00-00
Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 4KB-84314-01-00
Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-84714-41-00
Main 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 . . . . . . . . . . . . . . . . . . . . 214-11198-01-00
V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B4-17641-00-00
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BTG-11U1L-D0-00
Park Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . 5B4-26341-00-00
YXP1000A
Service Data
2004~2005
“ProHauler 1000”
(JW5)
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/A
Rear - 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
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