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Yamaha BANSHEE YFZ350 Owner's Manual

Other manuals for BANSHEE YFZ350: Service Manual

Summary of BANSHEE YFZ350

  • Page 1

    This a manual del propietario 3b5-28199-62 yfz350x manuel du propriÉtaire owner’s manual.

  • Page 2

    Printed in japan 2007.06-0.2x1 ! (e,f,s) yamaha motor co., ltd..

  • Page 3: Yfz350X

    This a 3b5-28199-62-e0 yfz350x owner’s manual.

  • Page 5

    Ebu17170 introduction ebu17320 congratulations on your purchase of the yamaha yfz350x. This atv represents the result of many years of yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this yamaha, you can now appreciate the high deg...

  • Page 6

    Ebu17330 important manual information ebu17341 failure to follow the warnings contained in this manual can result in serious in- jury or death. Particularly important information is distinguished in this manual by the following notations: * product and specifications are subject to change without no...

  • Page 7

    Ebu17350 important notice ebu17370 welcome to the yamaha world of motor sports! This atv is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this atv on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations bef...

  • Page 8

    Ebu17420 table of contents safety information .............................. 1-1 location of the warning and specification labels ............................ 2-1 description .............................................. 3-1 left view ..................................................... 3-1 right ...

  • Page 9

    Engine break-in ......................................... 6-4 parking ...................................................... 6-5 parking on a slope .................................... 6-6 accessories and loading ........................... 6-6 riding your atv ...................................... ...

  • Page 10

    Lubricating the steering shaft .................. 8-45 replacing a headlight bulb ...................... 8-45 adjusting a headlight beam ..................... 8-48 replacing the tail/brake light bulb ........... 8-48 removing a wheel ................................... 8-49 installing a wheel .........

  • Page 11

    1-1 1 2 3 4 5 6 7 8 9 10 11 ebu17430 safety information safety information ebu17592 an atv is not a toy and can be hazard- ous to operate. An atv handles differently from other vehicles, in- cluding motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such...

  • Page 12

    1-2 1 2 3 4 5 6 7 8 9 10 11 or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. ● never attempt wheelies, jumps, or other stunts. ● always inspect your atv each time you use it to make sure it is in safe operating cond...

  • Page 13

    1-3 1 2 3 4 5 6 7 8 9 10 11 backwards when climbing a hill. To avoid stall- ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointe...

  • Page 14

    1-4 1 2 3 4 5 6 7 8 9 10 11 cle, be sure it is kept upright and that the fuel cock is in the “off” position. Otherwise, fuel may leak out of the carburetor or fuel tank. ● gasoline is poisonous. If you should swal- low some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eye...

  • Page 15

    2-1 1 2 3 4 5 6 7 8 9 10 11 ebu17660 location of the warning and specification labels 1 2 3 4 5 6.

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    2-2 1 2 3 4 5 6 7 8 9 10 11 ebu17670 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a replace- ment label from your yamaha d...

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    2-3 1 2 3 4 5 6 7 8 9 10 11.

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    2-4 1 2 3 4 5 6 7 8 9 10 11.

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    2-5 1 2 3 4 5 6 7 8 9 10 11.

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    2-6 1 2 3 4 5 6 7 8 9 10 11.

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    3-1 1 2 3 4 5 6 7 8 9 10 11 ebu17680 description ebu17690 left view ebu17700 right view 1. Front shock absorber assembly 2. Radiator 3. Fuel cock 4. Rear shock absorber assembly 5. Spark arrester 6. Starter (choke) 7. Shift pedal 1 2 3 4 5 7 6 1. Tail/brake light 2. Seat 3. Kickstarter 4. Fuel tank ...

  • Page 22

    3-2 1 2 3 4 5 6 7 8 9 10 11 ebu17712 controls and instruments note: the atv you have purchased may differ slightly from the figures shown in this manual. 1. Clutch lever 2. Parking brake lock plate 3. Main switch 4. Brake lever 5. Throttle lever 6. Handlebar switches 1 2 3 4 6 5.

  • Page 23

    4-1 1 2 3 4 5 6 7 8 9 10 11 ebu17731 instrument and control functions ebu17760 main switch the positions of the main switch are as follows: on all electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cann...

  • Page 24

    4-2 1 2 3 4 5 6 7 8 9 10 11 ebu18061 handlebar switches ebu18070 engine stop switch “eng. Stop” set this switch to “run” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The...

  • Page 25

    4-3 1 2 3 4 5 6 7 8 9 10 11 before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. Warning ewb00250 malfunction of the throttle could make it diffi- cult to speed up or slow down when you need to...

  • Page 26

    4-4 1 2 3 4 5 6 7 8 9 10 11 and the maximum speed of the atv, turn the adjusting screw in direction (b). 3. Tighten the locknut. Warning ewb00240 improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an ac...

  • Page 27

    4-5 1 2 3 4 5 6 7 8 9 10 11 ebu18411 brake lever the brake lever is located at the right handlebar grip. To apply the front brake, pull the brake lever toward the handlebar grip. Ebu18432 brake pedal the brake pedal is located on the right side of the atv. To apply the rear brake, push down on the b...

  • Page 28

    4-6 1 2 3 4 5 6 7 8 9 10 11 wise, the engine will misfire, preventing normal op- eration. Warning ewb00220 ● always set the parking brake before starting the engine. The atv could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. ● al...

  • Page 29

    4-7 1 2 3 4 5 6 7 8 9 10 11 prematurely. Ebu18530 shift pedal this atv is equipped with a constant-mesh 6- speed transmission. The shift pedal is located on the left side of the engine and is used in combina- tion with the clutch when shifting. Ebu18650 kickstarter fold out the kickstarter lever, mo...

  • Page 30

    4-8 1 2 3 4 5 6 7 8 9 10 11 ebu18772 fuel make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Note: if knocking or pinging occurs, use a different brand 1. Fuel tank cap 1 1. Fuel level 2. Filler tube recommended fuel: premium unleaded g...

  • Page 31

    4-9 1 2 3 4 5 6 7 8 9 10 11 of gasoline or higher octane grade. Caution: ecb00060 use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the piston rings, as well as to the exhaust system. Warning ewb00310 ● do not overfill the fuel tank. Fu...

  • Page 32

    4-10 1 2 3 4 5 6 7 8 9 10 11 on with the fuel cock lever in this position, fuel flows to the carburetors. Turn the fuel cock lever to this position when starting the engine and riding. Res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the...

  • Page 33

    4-11 1 2 3 4 5 6 7 8 9 10 11 the starter (choke). Move the starter (choke) in direction (b) to turn off the starter (choke). See the “starting a cold engine” section on page 6-1 for proper operation. Ebu18870 seat to remove the seat pull the seat lock lever upward and pull up the seat at the rear. T...

  • Page 34

    4-12 1 2 3 4 5 6 7 8 9 10 11 ebu18990 adjusting the front shock absorber assemblies the spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby har...

  • Page 35

    4-13 1 2 3 4 5 6 7 8 9 10 11 warning ewb00400 always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. Ebu19100 adjusting the rear shock absorber assembly the spring...

  • Page 36

    4-14 1 2 3 4 5 6 7 8 9 10 11 note: ● a special wrench can be obtained at a yamaha dealer to make this adjustment. ● the spring preload setting is determined by measuring distance a, shown in the illustration. The shorter distance a is, the higher the spring preload; the longer distance a is, the low...

  • Page 37

    4-15 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00080 always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque. Rebound damping force turn the adjusting dial in direction (a) to increase the rebound damping force and thereby harden the damping, and in direction (b...

  • Page 38

    4-16 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00090 never turn an adjusting mechanism beyond the minimum and maximum settings. Note: although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual...

  • Page 39

    5-1 1 2 3 4 5 6 7 8 9 10 11 ebu19200 pre-operation checks ebu19222 pre-operation check list before operating this atv, be sure to check the items listed in the following table. Warning ewb00480 always inspect your atv each time you use it to make sure it is in safe operating condition. Always follow...

  • Page 40

    5-2 1 2 3 4 5 6 7 8 9 10 11 front brake ● check operation. If soft or spongy, have yamaha dealer bleed hydraulic system. ● check brake pads for wear, and replace if necessary. ● check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary. ● check hydraulic s...

  • Page 41

    5-3 1 2 3 4 5 6 7 8 9 10 11 ebu19550 fuel and 2-stroke engine oil mixing ratio if yamalube “r” oil is not available, select an oil from the following list. Caution: ecb00140 never mix two types of 2-stroke engine oil in the same batch. Always use the same type of oil to ensure maximum engine perform...

  • Page 42

    5-4 1 2 3 4 5 6 7 8 9 10 11 page 8-35.) if the pedal height is incorrect, have a yamaha dealer adjust it. ● check the operation of the lever and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have a yamaha dealer check the brake system. Brake...

  • Page 43

    5-5 1 2 3 4 5 6 7 8 9 10 11 ebu19791 tires warning ewb00601 use of improper tires on this atv, or operation of this atv with improper or uneven tire pres- sure, may cause loss of control, increasing your risk of accident. Pay attention to the following. ● the tires listed below have been approved by...

  • Page 44

    5-6 1 2 3 4 5 6 7 8 9 10 11 higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully. Ebu19820 measuring the tire pressure use the low-pressure tire gauge. Note: the low-pressure tire gauge is included as stan- dard equipment. Make two measurements o...

  • Page 45

    5-7 1 2 3 4 5 6 7 8 9 10 11 ebu19840 chassis fasteners make sure that all nuts, bolts and screws are prop- erly tightened. Ebu19850 instruments, lights and switches check that all instruments, lights and switches are working properly. Correct if necessary. 1. Tire wear limit.

  • Page 46

    6-1 1 2 3 4 5 6 7 8 9 10 11 ebu19880 operation ebu19900 read the owner’s manual carefully before riding the atv. Warning ewb00630 read the owner’s manual carefully to become familiar with all controls in order to help pre- vent any loss of control, which could cause an accident or injury. If there i...

  • Page 47

    6-2 1 2 3 4 5 6 7 8 9 10 11 ambient temp./starter (choke) position 6. Completely close the throttle lever and start the engine by kicking the kickstarter. 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engin...

  • Page 48

    6-3 1 2 3 4 5 6 7 8 9 10 11 ebu20520 shifting this atv has a 6-speed forward transmission. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to the closed...

  • Page 49

    6-4 1 2 3 4 5 6 7 8 9 10 11 wheelie, which would increase the chance of an accident, including an overturn. Ebu20650 to decelerate when slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has suff...

  • Page 50

    6-5 1 2 3 4 5 6 7 8 9 10 11 polish themselves to the correct operating clear- ances. During this period, prolonged full-throttle operation or any condition that might result in en- gine overheating must be avoided. 0–160 km (0–100 mi) or 0–10 hours avoid prolonged operation above 1/2 throttle. Vary ...

  • Page 51

    6-6 1 2 3 4 5 6 7 8 9 10 11 ebu20860 parking on a slope warning ewb00850 avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the atv to roll out of control, increasing the chance of an accident. If you must park on an incline, place the atv transversely across ...

  • Page 52

    6-7 1 2 3 4 5 6 7 8 9 10 11 ● choose only accessories designed for your atv. Your yamaha dealer has a variety of gen- uine yamaha accessories. Other accessories may also be available on the market. However, it is not possible for yamaha to test all non- yamaha accessories, nor control over their qua...

  • Page 53

    6-8 1 2 3 4 5 6 7 8 9 10 11 the more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail- er. ● allow more braking distance. A heavier atv takes longer to stop. ● avoid making ...

  • Page 54

    7-1 1 2 3 4 5 6 7 8 9 10 11 ebu21141 riding your atv.

  • Page 55

    7-2 1 2 3 4 5 6 7 8 9 10 11 ebu21611 getting to know your atv this atv is intended for recreational use by expe- rienced operators only. Even if you are an experi- enced operator of all other all terrain atvs or motorcycles, riding the atv requires special skills acquired through practice. Take your...

  • Page 56

    7-3 1 2 3 4 5 6 7 8 9 10 11 with engine size greater than 90 cc. Use by chil- dren of atvs that are not recommended for their age can lead to severe injury or death of the child. This atv is designed to carry operator only – passengers prohibited. Warning ewb01400 never carry a passenger. The long s...

  • Page 57

    7-4 1 2 3 4 5 6 7 8 9 10 11 warning ewb01410 never operate this atv without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operatin...

  • Page 58

    7-5 1 2 3 4 5 6 7 8 9 10 11 page 5-1 before riding for proper care of the atv and to ensure safety. Warning ewb01430 always inspect your atv each time you use it to make sure the atv is in safe operating con- dition. Always follow the inspection and main- tenance procedures and schedules described i...

  • Page 59

    7-6 1 2 3 4 5 6 7 8 9 10 11 loading and accessories as originally equipped, this atv is not designed to carry cargo or tow a trailer. If you choose to add ac- cessories so that you can carry cargo or tow a trail- er, you must use common sense and good judgment. Use extra caution when riding the atv ...

  • Page 60

    7-7 1 2 3 4 5 6 7 8 9 10 11 warning ewb01470 always keep both hands on the handlebars and both feet on the footboards of your atv during operation. Removing even one hand or foot can reduce your ability to control the atv or could cause you to lose your balance and fall off of the atv. If you remove...

  • Page 61

    7-8 1 2 3 4 5 6 7 8 9 10 11 installed and used according to instructions. Improper installation of accessories or modifi- cation of this atv may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized atv dealer. Exhaust system t...

  • Page 62

    7-9 1 2 3 4 5 6 7 8 9 10 11 while riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles. Watch carefully for other vehicles. Make sure you know your country’s laws and regulations before you ride on unpaved public...

  • Page 63

    7-10 1 2 3 4 5 6 7 8 9 10 11 ing terrain conditions when operating the atv. Warning ewb01540 do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the atv on such terrain. Failure to use extra care when operating on excess...

  • Page 64

    7-11 1 2 3 4 5 6 7 8 9 10 11 warning ewb01550 always mount a caution flag on the atv to make you more visible when operating in areas where you might not be seen by other vehicles. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”. Do not ride on private property witho...

  • Page 65

    7-12 1 2 3 4 5 6 7 8 9 10 11 these components. With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then release the parking brake. Open the throttle grad- ually, and at the same time, release the clutch le- ver slowly. Once the atv has attained adequa...

  • Page 66

    7-13 1 2 3 4 5 6 7 8 9 10 11 used to allow the atv to make turns quickly and easily. It is essential that this skill be learned first at low speed. Warning ewb01570 always follow proper procedures for turning as described in this owner’s manual. Practice turning at low speeds before attempting to tu...

  • Page 67

    7-14 1 2 3 4 5 6 7 8 9 10 11 changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the atv to tip. If the atv begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off...

  • Page 68

    7-15 1 2 3 4 5 6 7 8 9 10 11 if you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the atv around while you still have forward motion (provided you have the room to do so) and go down the hill. Warning ewb01600 never attempt to ...

  • Page 69

    7-16 1 2 3 4 5 6 7 8 9 10 11 ply the front brake gradually, or dismount the atv immediately on the uphill side. Warning ewb01731 use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: ● keep weight uphill. ● apply the brakes. ● lock the parking brake aft...

  • Page 70

    7-17 1 2 3 4 5 6 7 8 9 10 11 hill. Avoid sharp angles which could allow the atv to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear. Warning ewb01620 always follow proper procedures for going down hills as described in thi...

  • Page 71

    7-18 1 2 3 4 5 6 7 8 9 10 11 in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel. Warning ewb01631 never attempt to turn the atv around on any hill until you have mastered the turning tech- nique as...

  • Page 72

    7-19 1 2 3 4 5 6 7 8 9 10 11 them several times to let friction dry out the lin- ings. If the atv is operated through deep or fast flowing water, the tires may float, causing loss of traction and loss of control, which could lead to an accident. Test your brakes after leaving the water. Do not conti...

  • Page 73

    7-20 1 2 3 4 5 6 7 8 9 10 11 riding over rough terrain riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the atv or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping t...

  • Page 74

    7-21 1 2 3 4 5 6 7 8 9 10 11 slide. Applying the brakes or accelerating is not recommended until you have corrected the slide. With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both sta...

  • Page 75

    7-22 1 2 3 4 5 6 7 8 9 10 11 to climb: turn the atv around if you still have forward speed. If not, stop, dismount on the uphill side of the atv and physically turn the atv around. If the atv starts to slip backwards, do not use the rear brake – the atv may tip over on top of you. Dismount the atv o...

  • Page 76

    8-1 1 2 3 4 5 6 7 8 9 10 11 ebu28781 periodic maintenance and minor repair ebu21670 safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your atv in the safest and best operating condition possible. The most important points of inspection, adjustment, and...

  • Page 77

    8-2 1 2 3 4 5 6 7 8 9 10 11 the service information included in this manual and the tools provided in the owner’s tool kit are in- tended to assist you in the performance of preven- tive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform cert...

  • Page 78

    8-3 1 2 3 4 5 6 7 8 9 10 11 ebu21742 periodic maintenance chart for the emission control system note: ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inte...

  • Page 79

    8-4 1 2 3 4 5 6 7 8 9 10 11 6 spark arrester ● clean. √ √ √ no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320

  • Page 80

    8-5 1 2 3 4 5 6 7 8 9 10 11 ebu21864 general maintenance and lubrication chart no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 air filter element ● clean and replace if...

  • Page 81

    8-6 1 2 3 4 5 6 7 8 9 10 11 9 * wheel hub bearings ● check for looseness or damage, and replace if necessary. √ √ √ √ 10 * upper and lower arm pivots ● lubricate with lithium-soap-based grease. √ √ √ 11 drive chain ● check chain slack and adjust if necessary. ● check rear wheel alignment and correct...

  • Page 82

    8-7 1 2 3 4 5 6 7 8 9 10 11 ebu23070 note: ● the air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● hydraulic brake service ● regularly check and, if necessary, correct the brake fluid level. ● every two years replace the internal components of the brake mast...

  • Page 83

    8-8 1 2 3 4 5 6 7 8 9 10 11 ebu28320 checking the spark plugs the spark plugs are important engine compo- nents, which are easy to check. Since heat and de- posits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and...

  • Page 84

    8-9 1 2 3 4 5 6 7 8 9 10 11 stead, have a yamaha dealer check the atv. 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. To install a spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the...

  • Page 85

    8-10 1 2 3 4 5 6 7 8 9 10 11 a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4. Install the spark plug cap. Ebu23341 transmission oil the transmission oil level should be c...

  • Page 86

    8-11 1 2 3 4 5 6 7 8 9 10 11 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the transmission to col- lect the used oil. 4. Remove the oil filler cap and the drain bolt to drain the oil from the transmission. 5. Install the drain bolt, and then ...

  • Page 87

    8-12 1 2 3 4 5 6 7 8 9 10 11 ebu23470 coolant the coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. Ebu23501 to check the coolant level 1. Place the atv on a level surface. Note: th...

  • Page 88

    8-13 1 2 3 4 5 6 7 8 9 10 11 5. Remove the reservoir cap, add coolant or dis- tilled water to the maximum level mark, and then install the reservoir cap. Caution: ecb00401 ● if coolant is not available, use distilled water or soft tap water instead. Do not use hard wa- ter or salt water since it is ...

  • Page 89

    8-14 1 2 3 4 5 6 7 8 9 10 11 when opening. Allow any remaining pressure to escape before completely removing the cap. 1. Place the atv on a level surface. 2. Remove the radiator cover by removing the bolts. 3. Place a container under the engine and re- move the coolant drain bolts. 4. Remove the rad...

  • Page 90

    8-15 1 2 3 4 5 6 7 8 9 10 11 5. Remove the coolant reservoir cap. 6. Disconnect the hose on the coolant reservoir side and drain the coolant from the coolant reservoir. 1. Radiator cap 1 1. Coolant reservoir cap 1.

  • Page 91

    8-16 1 2 3 4 5 6 7 8 9 10 11 7. After draining the coolant, thoroughly flush the cooling system with clean tap water. 8. Replace the coolant drain bolt washers if they are damaged, and then tighten the coolant drain bolts to the specified torque. 9. Connect the coolant reservoir hose. 10. Pour the r...

  • Page 92

    8-17 1 2 3 4 5 6 7 8 9 10 11 tected against frost and corrosion. ● if water has been added to the coolant, have a yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- erwise the effectiveness of the coolant will be reduced. 12. Install the radiator cap, start the eng...

  • Page 93

    8-18 1 2 3 4 5 6 7 8 9 10 11 3. Pull the air filter element out of the air filter case. 4. Remove the lock plate by turning it, and then remove the sponge material from the air filter element frame. 1. Air filter case cover 2. Air filter case cover holder 1 2 2 1. Air filter element lock plate 1.

  • Page 94

    8-19 1 2 3 4 5 6 7 8 9 10 11 5. Wash the sponge material gently but thor- oughly in solvent. Warning ewb01940 always use parts cleaning solvent to clean the sponge material. Never use low-flash-point solvents or gasoline to clean the sponge mate- rial because the engine could catch fire or ex- plode...

  • Page 95

    8-20 1 2 3 4 5 6 7 8 9 10 11 turning it. 10. Insert the air filter element into the air filter case, and then install the air filter case cover by hooking the holders onto the air filter case. 11. Install the seat. Note: the air filter element should be cleaned every 20– 40 hours. It should be clean...

  • Page 96

    8-21 1 2 3 4 5 6 7 8 9 10 11 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Make sure the gasket is properly positione...

  • Page 97

    8-22 1 2 3 4 5 6 7 8 9 10 11 touching exhaust components. Ebu23992 changing the carburetor settings in extremely cold weather, it is necessary to change the carburetor settings to maintain opti- mum engine performance and to prevent engine damage. Warning ewb01990 ● improperly servicing or adjusting...

  • Page 98

    8-23 1 2 3 4 5 6 7 8 9 10 11 carburetor setting chart 1. Standard position: groove 3 1 temperature altitude 0–1500 m (5000 ft) above 1500 m (5000 ft) main jet jet needle pilot air screw main jet jet needle pilot air screw above 0°c (32°f) #200 3rd groove 2.0 turns out #190 3rd groove 2 1/2 turns out...

  • Page 99

    8-24 1 2 3 4 5 6 7 8 9 10 11 changing the settings of the carburetors to change the settings of the carburetors, you need to disassemble and remove them. Follow the procedures for both carburetors. Disassembling and removing the carburetors 1. Turn the fuel cock to the “off” position. 2. Turn out th...

  • Page 100

    8-25 1 2 3 4 5 6 7 8 9 10 11 8. Remove the mixing chamber cap securing plate by removing the screw. 9. Loosen the carburetor joint screws. 1. Air filter case cover 2. Air filter case cover holder 1 2 2 1. Mixing chamber cap securing plate 2. Screw 2 1.

  • Page 101

    8-26 1 2 3 4 5 6 7 8 9 10 11 10. Remove the mixing chamber cap. 11. Remove the throttle cable from the throttle valve, and then remove the throttle cable hold- er by removing the screws. 1. Joint screw 1 1 1 1 1. Throttle cable 2. Throttle valve 3. Throttle cable holder 4. Screw 1 2 3 4.

  • Page 102

    8-27 1 2 3 4 5 6 7 8 9 10 11 12. Remove the carburetor, and then remove the float chamber by removing the screws. 13. Remove the float and needle valve. 14. Change the main jet and the jet needle clip po- sition. Note: ● optional main jets can be obtained at a yamaha dealer. ● after the jet needle c...

  • Page 103

    8-28 1 2 3 4 5 6 7 8 9 10 11 assembling and installing the carburetors assemble and install both carburetors by the fol- lowing steps. 1. Install the needle valve and float. 2. Install the float chamber by installing the screws. 3. Install the carburetor and tighten the joint screws. 4. Assemble the...

  • Page 104

    8-29 1 2 3 4 5 6 7 8 9 10 11 2. Push the throttle lever forward until it stops and hold it in this position. 3. Check through each carburetor window to see if the punch mark on the throttle valve is at the specified position. 4. If not, loosen the locknut and turn the adjust- ing nut until the speci...

  • Page 105

    8-30 1 2 3 4 5 6 7 8 9 10 11 tion chart. Note: ● a diagnostic tachometer is needed to make this adjustment. ● the carburetor synchronization and the throttle cable free play must be checked, and adjusted if necessary, before adjusting the engine idling speed. 1. Start the engine and warm it up. Note...

  • Page 106

    8-31 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00510 ● the throttle stop screws were preset at the factory. When adjusting the idling speed, turn both throttle stop screws the same amount, otherwise the carburetor synchroni- zation will be incorrect. ● adjusting the pilot air screws and the idling speed a...

  • Page 107

    8-32 1 2 3 4 5 6 7 8 9 10 11 the throttle cable free play, turn the adjusting bolt in direction (b). 3. Tighten the locknut. Ebu24130 checking the front and rear brake pads the front and rear brake pads must be checked for wear at the intervals specified in the periodic main- tenance and lubrication...

  • Page 108

    8-33 1 2 3 4 5 6 7 8 9 10 11 without having to disassemble the brake. To check the brake pad wear, check the position of the wear indicator while applying the brake. If a brake pad has worn to the point that the wear indicator almost touches the brake disc, have a yamaha dealer re- place the brake p...

  • Page 109

    8-34 1 2 3 4 5 6 7 8 9 10 11 rear brake observe these precautions: ● when checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. ...

  • Page 110

    8-35 1 2 3 4 5 6 7 8 9 10 11 intervals specified in the periodic maintenance and lubrication chart. The brake lever should have a free play of zero mm (zero in) as shown. If the free play is incorrect, have a yamaha dealer check the brake system. Warning ewb02070 operating with improperly serviced o...

  • Page 111

    8-36 1 2 3 4 5 6 7 8 9 10 11 warning ewb02110 operating with improperly serviced or adjust- ed brakes could cause loss of braking ability, which could lead to an accident. After servicing: ● make sure the brakes operate smoothly and that the brake pedal position is correct. ● make sure the brakes do...

  • Page 112

    8-37 1 2 3 4 5 6 7 8 9 10 11 3. Loosen the locknut and the adjusting bolt at the rear brake caliper. 4. Turn the adjusting bolt at the clutch lever in di- rection (a) to increase the cable length, and in direction (b) to decrease it. Note: if the cable length cannot be adjusted to specifica- tion, c...

  • Page 113

    8-38 1 2 3 4 5 6 7 8 9 10 11 warning ewb02090 operating with improperly serviced or adjust- ed brakes could cause the brakes to malfunc- tion, resulting in reduced braking performance. This could increase the chance of a collision or accident. After adjusting the parking brake free play, block the r...

  • Page 114

    8-39 1 2 3 4 5 6 7 8 9 10 11 shown. If the free play is incorrect, adjust it as fol- lows. 1. Loosen the locknut at the clutch lever. 2. To increase the clutch lever free play, turn the adjusting bolt in direction (a), and to decrease it, turn the bolt in direction (b). 3. Tighten the locknut. Note:...

  • Page 115

    8-40 1 2 3 4 5 6 7 8 9 10 11 3. If the drive chain slack is incorrect, adjust it as follows. To adjust the drive chain slack 1. Loosen the axle holding nuts. 2. Loosen the locknut on each side of the swing- arm. To tighten the drive chain, turn the ad- justing bolts in direction (a). To loosen the d...

  • Page 116

    8-41 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00541 improper drive chain slack will overload the en- gine as well as other vital parts of the atv and can lead to drive chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits. 3. Tighten the locknu...

  • Page 117

    8-42 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00560 the drive chain must be lubricated after wash- ing the atv or riding in the rain. 1. Clean the drive chain with kerosene and a small soft brush. Caution: ecb00570 to prevent damaging the o-rings, do not clean the drive chain with steam cleaners, high-pr...

  • Page 118

    8-43 1 2 3 4 5 6 7 8 9 10 11 ebu24921 checking and lubricating the brake and clutch levers the operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Ebu24931 checking and lubricating the brake and shift pedals the operati...

  • Page 119

    8-44 1 2 3 4 5 6 7 8 9 10 11 ebu25031 lubricating the upper and lower arm pivots the upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun. Recommended lubricant: lithium-soap-bas...

  • Page 120

    8-45 1 2 3 4 5 6 7 8 9 10 11 left side right side ebu25101 lubricating the steering shaft the steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Ebu26881 replacing a headlight bulb if a headlight bulb burns out, replace it as follows. ...

  • Page 121

    8-46 1 2 3 4 5 6 7 8 9 10 11 1. Remove the headlight unit by removing the screw. 2. Remove the headlight bulb holder cover. 3. Remove the bulb holder by turning it counter- clockwise. 1. Screw 1 1. Headlight bulb holder cover 1.

  • Page 122

    8-47 1 2 3 4 5 6 7 8 9 10 11 4. Remove the defective bulb. Warning ewb02200 a headlight bulb is hot when it is on and imme- diately after it is turned off. Wait for the bulb to cool before touching or removing it. You can be burned, or a fire could start if the bulb touches something flammable. 5. P...

  • Page 123

    8-48 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00680 make sure the bulb holder cover is securely fit- ted over the bulb holder and seated against the reflector. 7. Place the headlight unit in the original posi- tion, and then install the screw. 8. Adjust the headlight beam if necessary. Ebu25550 adjusting...

  • Page 124

    8-49 1 2 3 4 5 6 7 8 9 10 11 follows. 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 4....

  • Page 125

    8-50 1 2 3 4 5 6 7 8 9 10 11 front rear 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Ebu25660 installing a wheel 1. Install the wheel and the nuts. 2. Lower the atv to the ground. 3. Tighten the wheel nuts to the specified tor...

  • Page 126

    8-51 1 2 3 4 5 6 7 8 9 10 11 ebu25740 troubleshooting although yamaha atvs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power. The fo...

  • Page 127

    8-52 1 2 3 4 5 6 7 8 9 10 11 ebu25841 troubleshooting charts starting problems or poor engine perfor- mance check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Supply fuel. Operate the kickstarter. 2. Compression there is compression. There is no compression. Check...

  • Page 128

    8-53 1 2 3 4 5 6 7 8 9 10 11 engine overheating warning ewb02290 wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening. Allow any remaining pressure to escape be...

  • Page 129

    9-1 1 2 3 4 5 6 7 8 9 10 11 ebu25860 cleaning and storage ebu25920 cleaning frequent, thorough cleaning of your atv will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the atv: a. Block off the end of the exh...

  • Page 130

    9-2 1 2 3 4 5 6 7 8 9 10 11 increasing the chance of an accident. Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. Ebu25951 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a...

  • Page 131

    9-3 1 2 3 4 5 6 7 8 9 10 11 with oil.) e. Remove the spark plug caps from the spark plugs, and then install the spark plugs and the spark plug caps. 6. Lubricate all control cables and the pivoting points of all levers and pedals. 7. Check and, if necessary, correct the tire air pressure, and then b...

  • Page 132

    10-1 1 2 3 4 5 6 7 8 9 10 11 ebu25960 specifications ebu2597a dimensions: overall length: 1855 mm (73.0 in) overall width: 1100 mm (43.3 in) overall height: 1080 mm (42.5 in) seat height: 800 mm (31.5 in) wheelbase: 1280 mm (50.4 in) ground clearance: 135 mm (5.3 in) minimum turning radius: 3600 mm ...

  • Page 133

    10-2 1 2 3 4 5 6 7 8 9 10 11 fuel: recommended fuel: premium unleaded gasoline only fuel tank capacity: 12.0 l (3.17 us gal) (2.64 imp.Gal) fuel reserve amount: 2.5 l (0.66 us gal) (0.55 imp.Gal) carburetor: manufacturer: mikuni type x quantity: vm26ss x 2 spark plug (s): manufacturer/model: ngk/br8...

  • Page 134

    10-3 1 2 3 4 5 6 7 8 9 10 11 size: at20 x 10-9 manufacturer/model: dunlop/kt877a loading: maximum loading limit: 100.0 kg (220 lb) (total weight of rider, cargo, accessories, and tongue) tire air pressure (measured on cold tires): recommended: front: 30 kpa (4.4 psi) (0.30 kgf/cm 2 ) rear: 30 kpa (4...

  • Page 135

    10-4 1 2 3 4 5 6 7 8 9 10 11 wheel travel: 220 mm (8.7 in) electrical system: ignition system: cdi charging system: ac magneto headlight: bulb type: krypton bulb bulb voltage, wattage x quantity: headlight: 12 v, 30.0/30.0 w × 2 tail/brake light: 12 v, 5.0/21.0 w × 1.

  • Page 136

    11-1 1 2 3 4 5 6 7 8 9 10 11 ebu26000 consumer information ebu26011 identification numbers record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a yamaha dealer or for ref- erence...

  • Page 137

    11-2 1 2 3 4 5 6 7 8 9 10 11 note: the vehicle identification number is used to identi- fy your atv. Ebu26050 model label the model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spar...

  • Page 138

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning............................................ 8-17 b brake and clutch levers, checking and lubricating ....... 8-43 brake and shift pedals, checking and lubricating ......... 8-43 brake fl...

  • Page 139

    M main switch .....................................................................4-1 maintenance and lubrication chart ..................................8-5 maintenance chart, emission control system ..................8-3 model label....................................................................

  • Page 140

    Printed in japan 2007.06-0.2x1 ! (e) yamaha motor co., ltd. Printed on recycled paper.