differential YAMAHA YFM600FWA 2001 Owners Manual

EBU00015
CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ....................... 1-1
SAFETY INFORMATION ........................ 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION .................................... 3-1
Identification number records ........... 3-3
Key identification number ................. 3-5
Vehicle identification number ........... 3-5
Model label ......................................... 3-7
CONTROL FUNCTIONS ......................... 4-1
Main switch......................................... 4-1
Indicator lights .................................... 4-3
Oil temperature warning light
checking method .............................. 4-5
Speedometer .................................... 4-11
Fuel gauge ........................................ 4-11
Handlebar switches .......................... 4-13
Throttle lever .................................... 4-19
Speed limiter .................................... 4-21
Front brake lever .............................. 4-23Rear brake pedal and lever.............. 4-25
Parking brake .................................... 4-27
Drive select lever .............................. 4-29
Recoil starter..................................... 4-29
Fuel tank cap..................................... 4-31
Fuel cock ........................................... 4-33
Starter (choke) “ ” ........................ 4-35
Seat ................................................... 4-37
Storage box ...................................... 4-39
Front carrier ...................................... 4-39
Rear carrier ....................................... 4-39
Rear shock absorber
adjustment...................................... 4-41
Auxiliary DC connector .................... 4-43
PRE-OPERATION CHECKS .................... 5-1
Front and rear brakes......................... 5-7
Fuel .................................................... 5-11
Engine oil .......................................... 5-15
Final gear oil/Differential
gear oil ............................................ 5-19
Throttle lever .................................... 5-19
Fittings and Fasteners...................... 5-21
Lights................................................. 5-211
2
3
4
5

Switches ........................................... 5-21
Tires .................................................. 5-23
How to measure tire pressure ........ 5-27
Tire wear limit .................................. 5-29
OPERATION ........................................... 6-1
Starting a cold engine ....................... 6-3
Starting a warm engine ..................... 6-9
Warming up ........................................ 6-9
Drive select lever operation and
reverse driving ............................... 6-11
Reverse lock release wire ................ 6-15
Engine break-in ................................ 6-17
Parking .............................................. 6-19
Parking on a slope ........................... 6-21
Accessories and loading ................. 6-23
RIDING YOUR ATV ................................ 7-1
Getting to know your ATV ................. 7-3
Ride with care and good
judgement ........................................ 7-5
Be careful where you ride ............... 7-27
Turning your ATV ............................ 7-39
Climbing uphill ................................. 7-45
Riding downhill ................................ 7-55
Crossing a slope ............................... 7-59Crossing through shallow
water ............................................... 7-63
Riding over rough terrain ................ 7-67
Sliding and skidding ........................ 7-69
What to do if ..................................... 7-73
What to do ........................................ 7-73
PERIODIC MAINTENANCE AND
ADJUSTMENT ....................................... 8-1
Owner’s manual and tool kit ............. 8-3
Periodic maintenance/
lubrication ........................................ 8-7
Engine oil .......................................... 8-15
Final gear oil ..................................... 8-25
Differential gear oil .......................... 8-29
Front axle boots ............................... 8-33
Spark plug inspection ...................... 8-35
Air filter cleaning.............................. 8-39
Carburetor adjustment .................... 8-45
Idle speed adjustment ..................... 8-47
Valve clearance adjustment ............ 8-49
Throttle lever adjustment ................ 8-49
Front brake pad inspection ............. 8-51
Rear brake shoe inspection ............. 8-51
Inspecting the brake fluid level ....... 8-53
Brake fluid replacement .................. 8-57
6
7
8

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brake• Check operation, free play, fluid level and fluid leakage.
• Fill with DOT 4 (or DOT 3) brake fluid if necessary.5-7 ~ 5-9,
8-51 ~ 8-67
Rear brake• Check operation and free play.
Fuel• Check fuel level.
• Fill with fuel if necessary.5-11 ~ 5-13
Engine oil• Check oil level.
• Fill with oil if necessary.5-15 ~ 5-17,
8-15 ~ 8-23
Final gear oil/
Differential gear oil• Check for leakage. 5-19, 8-25 ~ 8-33
Throttle• Check for proper throttle cable operation. 5-19, 8-49
Wheels and tires• Check tire pressure, wear and damage.5-23 ~ 5-29,
8-71 ~ 8-73
Fittings and Fasteners• Check all fittings and fasteners. 5-21
Lights• Check for proper operation. 5-21, 8-83
Front axle boots• Check for damage. 8-33

5-19
EBU00495
Final gear oil/Differential gear oil
Make sure the final gear oil/differential gear oil
is at the specified level. Add oil as necessary.
(See pages 8-25 ~ 8-33.)
If desired, an SAE 80W90 hypoid gear oil may
be used for all conditions.
NOTE:
GL-4 is a quality and additive rating. GL-5 or
GL-6 rated hypoid gear oils may also be used.
EBU00151
Throttle lever
Check to see that the throttle lever operates
correctly. It must open smoothly and spring
back to idle position when released. Repair as
necessary for proper operation.Recommended oil:
SAE 80 API GL-4 Hypoid gear oil

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*• Check valve clearance.
• Adjust if necessary.
Spark plug• Check condition.
• Adjust gap and clean.
• Replace if necessary.
Air filter• Clean.
• Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Carburetor*• Check idle speed/starter operation.
• Adjust if necessary.
Crankcase breather
system*• Check breather hose for cracks or damage.
• Replace if necessary.
Exhaust system*• Check for leakage.
• Retighten if necessary.
• Replace gasket(s) if necessary.
Fuel line*• Check fuel hose for cracks or damage.
• Replace if necessary.
Engine oil• Replace (Warm engine before draining).
Engine oil filter• Replace.
Engine oil strainer*• Clean.
Final gear oil• Check oil level/oil leakage.
• Replace every 12 months.
Differential gear oil
Front brake*• Check operation/fluid leakage/see NOTE page 8-8.
• Correct if necessary.
Rear brake*• Check operation.
• Adjust if necessary.
V-belt*• Check operation.
• Check for cracks or damage every 12 months or
2,400 km whichever comes first.

8-29
7. Install the filler bolt and tighten to the
specified torque.
8. Check for oil leakage. If oil leakage is
found, check for the cause.
9. Install the final gear case cover.
EBU00706
Differential gear oil
Differential gear oil measurement
1. Place the machine on a level place.
2. Remove the oil filler bolt and check the oil
level. It should be up to the brim of the
hole. If the level is low, add sufficient oil to
raise it to the specified level.
CAUTION:
Be sure no foreign material enters the differen-
tial gear case. Tightening torque:
Filler bolt (final gear case):
23 Nm (2.3 m·kg)1. Filler bolt 2. Correct oil level
1. Boulon de l’orifice de remplissage 2. Niveau d’huile correct
1. Perno del orificio de llenado 2. Nivel de aceite correcto

8-31
3. Install the oil filler bolt and tighten it to the
specified torque.
Differential gear oil replacement
1. Place the machine on a level place.
2. Place a container under the differential
gear case to catch the oil.
3. Remove the filler bolt and drain bolt to
drain the oil.
4. Install the drain bolt and tighten it to the
specified torque. Tightening torque:
Oil filler bolt:
23 Nm (2.3 m·kg)
Tightening torque:
Drain bolt:
20 Nm (2.0 m·kg)
1. Drain bolt
1. Boulon de vidange
1. Perno de drenaje

8-33
5. Fill the differential gear case with oil.
CAUTION:
Be sure no foreign material enters the differen-
tial gear case.
6. Install the filler bolt and tighten it to the
specified torque.
7. Check for oil leakage. If oil leakage is
found, check for the cause.
EBU00283
Front axle boots
Check the protective boots for holes or tears. If
any damage is found, have them replaced by a
Yamaha dealer.Recommended oil:
SAE 80 API “GL-4” Hypoid gear oil
Oil quantity:
Periodic oil change:
0.67 L
Total amount:
0.7 L
1. Front axle boot (× 2 each side)
1. Soufflet d’axe avant (× 2 de chaque côté)
1. Guardapolvo de eje delantero (× 2 en cada lado)

10-3
Final gear oil:
Type SAE 80 API “GL-4” Hypoid gear oil
Quantity
Periodic oil change 0.19 L
Total amount 0.22 L
Differential gear oil:
Type SAE 80 API “GL-4” Hypoid gear oil
Quantity
Periodic oil change 0.67 L
Total amount 0.70 L
Air filter: Wet type element
Fuel:
Type Regular gasoline
For Europe: Regular unleaded gasoline
For Oceania and South Africa: Unleaded fuel only
Fuel tank capacity 19 L
Fuel reserve amount 3 L
Carburetor:
Type/quantity BST 40/1
Manufacturer MIKUNIModel YFM600FWA